Service and Repair Manual
Serial Number Range
Z-80/60
from Z80134592 to
Z8016H-6399
from Z80H-6400
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268556
Rev A2
September 2016
Service and Repair Manual
September 2016
Introduction
Intr oducti on
Intr oducti on
Important
Technical Publications
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2015 by Terex Corporation
1268556 Rev A, September 2015
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc..
ii
Part No. 1268556
September 2016
Service and Repair Manual
Introduction
Revision History
Revision
Date
A
9/2015
A1
11/2015
Section
Procedure / Page / Description
Initial Release
Schematics
Added new serial number (from Z8013-4592)
Added Electrical Schematic
(from Z8013-4592 to Z8015-5653)
A2
9/2016
Introduction
Serial Number Legend
Specifications
GM 3.0L engine
Fault Codes
GM 3.0L engine
Schematics
GM 3.0L engine; Hydraulic Schematics
Reference Examples:
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Schematics, Legends and schematics
Part No. 1268556
iii
Service and Repair Manual
September 2016
Introduction
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
iv
4 Serial number (stamped on chassis)
5 Serial label (located under cover)
Part No. 1268556
September 2016
Service and Repair Manual
Safety Rules
Section 1
Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 1268556
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Service and Repair Manual
September 2016
Safety Rules
Personal Safety
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
vi
Part No. 1268556
September 2016
Table of Contents
Introduction
Introduction .......................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1
Safety Rules .......................................................................................................... v
General Safety Rules ............................................................................................. v
Section 2
Specifications ....................................................................................................... 1
Machine Specifications........................................................................................... 1
Performance Specifications ................................................................................... 1
Hydraulic Specification ........................................................................................... 2
Hydraulic Component Specifications ..................................................................... 4
Continental TME27 Engine Specifications ............................................................. 6
GM 3.0L Engine Specifications .............................................................................. 7
Deutz TD2011L04i Engine Specifications .............................................................. 8
Deutz TD 2.9 Engine Specifications ....................................................................... 9
Perkins 404F-22T Engine Specifications ............................................................. 10
Perkins 804D-33 Engine Specifications ............................................................... 11
Machine Torque Specifications ............................................................................ 12
Hydraulic Hose and Fitting Torque Specifications ............................................... 13
Torque Procedure ................................................................................................ 14
SAE and Metric Fasteners Torque Charts ........................................................... 16
Part No. 1268556
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September 2016
Table of Contents
Section 3
Repair Procedures ............................................................................................. 17
Introduction .......................................................................................................... 17
Platform Controls ............................................................................................... 19
Platform Controls ................................................................................................. 19
1-1 Platform Circuit Board .................................................................................... 20
How to Remove the LED Circuit Board .......................................................... 21
1-2 Joysticks - How to Calibrate a Joystick ......................................................... 21
How to Reset a Proportional Valve Coil Default ............................................. 25
How to Set the Function Thresholds and Default Functions Speeds ............. 25
How to Adjust the Function Speeds ............................................................... 27
How to Adjust the Function Ramp Rate Setting ............................................. 28
Platform Components ....................................................................................... 28
2-1 Platform.......................................................................................................... 28
2-2 Platform Leveling Cylinder ............................................................................. 29
How to Remove the Platform Leveling Cylinder ............................................. 29
How to Bleed the Platform Leveling Cylinder ................................................. 30
2-3 Platform Rotator ............................................................................................. 31
How to Bleed the Platform Rotator ................................................................. 32
2-4 Platform Overload System (if equipped) ........................................................ 33
2-5 Platform Overload Recovery Message .......................................................... 36
Jib Boom Components ...................................................................................... 37
3-1 Jib Boom ........................................................................................................ 37
3-2 Jib Boom Lift Cylinder .................................................................................... 39
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Part No. 1268556
September 2016
Table of Contents
Boom Components ............................................................................................ 40
4-1 Primary Boom Cable Track ............................................................................ 41
How to Repair the Primary Boom Cable Track ............................................... 43
4-2 Primary Boom ................................................................................................ 44
How to Shim the Primary Boom ...................................................................... 44
How to Disassemble the Primary Boom ......................................................... 46
4-3 Primary Boom Lift Cylinder ............................................................................ 47
4-4 Primary Boom Extension Cylinder ................................................................. 48
4-5 Primary Boom Angle Sensor .......................................................................... 50
How to Replace the Primary Boom Angle Sensor .......................................... 50
How to Calibrate the Primary Boom Angle Sensor ......................................... 51
4-6 Secondary Boom Cable Track ....................................................................... 53
How to Remove the Secondary Boom Cable Track ....................................... 53
How to Repair the Secondary Boom Cable Track .......................................... 53
4-7 Secondary Boom............................................................................................ 54
4-8 Secondary Boom Lift Cylinder ....................................................................... 55
4-9 Secondary Boom Extension Cylinder ............................................................ 57
Engines ............................................................................................................... 59
5-1 RPM Adjustment ............................................................................................ 59
5-2 Flex Plate ....................................................................................................... 59
How to Remove the Flex Plate ....................................................................... 59
How to Install the Flex Plate ........................................................................... 62
How to install the Pump and Bell Housing Assembly ..................................... 63
5-3 How to Access Perkins 404F Engine Regeneration Service ......................... 64
Ground Controls................................................................................................. 66
6-1 Bypass/Recovery Key Switch ........................................................................ 66
How to Use the Recovery Mode ..................................................................... 68
6-2 Circuit Boards ................................................................................................. 69
6-3 Membrane Decal ............................................................................................ 70
Display Module ................................................................................................... 71
Part No. 1268556
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September 2016
Table of Contents
Hydraulic Pumps ................................................................................................ 79
7-1 Function Pump ............................................................................................... 79
7-2 Drive Pump .................................................................................................... 80
How to Prime the Pump .................................................................................. 81
Manifolds ............................................................................................................ 82
8-1 Function Manifold Components - View 1 ....................................................... 82
8-2 Function Manifold Components - View 2 ....................................................... 84
8-3 Valve Adjustments - Function Manifold ......................................................... 86
How to Adjust the System Relief Valve .......................................................... 86
How to Adjust the Primary Boom Down Relief Valve ..................................... 87
How to Adjust the Primary Boom Extend Relief Valve ................................... 88
How to Adjust the Secondary Boom Up Relief Valve ..................................... 89
How to Adjust the Secondary Boom Down Relief Valve ................................ 90
How to Adjust the Secondary Boom Extend Relief Valve .............................. 91
How to Adjust the Platform Manifold Relief Valve .......................................... 91
8-4 Platform Manifold ........................................................................................... 92
8-5 Turntable Rotation Manifold........................................................................... 94
8-6 Platform Rotate Manifold ............................................................................... 95
8-7 Two Wheel Steer and Oscillate Manifold ....................................................... 96
How to Adjust the Oscillate Relief Valve ........................................................ 98
8-8 Four Wheel Steer and Oscillate Manifold .................................................... 100
How to Adjust the Oscillate Relief Valve ...................................................... 104
8-9 Oil Diverter Manifold Components (welder option) ...................................... 105
8-10 Traction Manifold Components, 2WD ........................................................ 106
8-11 Valve Adjustments, 2WD Traction Manifold .............................................. 108
8-12 Traction Manifold Components, 4WD ........................................................ 110
8-13 Valve Adjustments, 4WD Traction Manifold .............................................. 112
8-14 Valve Coils ................................................................................................. 113
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Part No. 1268556
September 2016
Table of Contents
Turntable Rotation Components .................................................................... 115
9-1 Turntable Rotation Assembly ....................................................................... 115
How to Adjust the Turntable Rotation Gear Backlash .................................. 116
Axle Components ............................................................................................. 117
10-1 Steer Sensors ............................................................................................ 117
How to Measure the Tire Alignment.............................................................. 117
How to Adjust a Steer Sensor ....................................................................... 118
How to Calibrate the Steer Sensors.............................................................. 119
How to Adjust the Oscillate Limit Switches ................................................... 120
10-2 Oscillating Axle Cylinders .......................................................................... 121
Section 4
Fault Codes ....................................................................................................... 122
Introduction ......................................................................................................... 122
Control System Fault Codes ........................................................................... 123
How to Read Control System Fault Codes ........................................................ 123
How to Clear Secondary Boom Safety Switch Faults ........................................ 123
Fault Code Display - Deutz and Perkins Models ........................................... 131
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and
Perkins 404F-22 Models ....................................................................... 131
Deutz D 2.9 L4 Engine Fault Codes ................................................................ 132
Perkins 404F-22 Engine Fault Codes ............................................................. 143
Continental TME27 Engine Fault Codes ........................................................ 145
How to Retrieve Continental Engine Fault Codes ........................................ 145
How to Clear Engine Fault Codes from the ECM ......................................... 145
Continental TME27 Engine Fault Codes....................................................... 146
GM 3.0L Engine Fault Codes ........................................................................... 151
GM Fault Code Chart ......................................................................................... 151
Part No. 1268556
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September 2016
Table of Contents
Section 5
Schematics ....................................................................................................... 156
Introduction ........................................................................................................ 156
Wire Circuit Legend ........................................................................................... 157
Wire Color Legend ............................................................................................. 161
Limit Switches and Angle Sensors..................................................................... 166
Drive Chassis and Platform Controller Pin Legend ........................................... 168
Turntable Controller Pin Legend ........................................................................ 169
Relay and Fuse Panel Legends ......................................................................... 170
Electrical Symbol Legend .................................................................................. 172
Hydraulic Symbols Legend ................................................................................ 173
Electrical Schematics ...................................................................................... 174
Electrical Schematic - Engine Options, Deutz TD2.9 Engine ............................ 175
Electrical Schematic - Engine Options, Deutz TD2.9 Engine Harness.............. 176
Electrical Schematic - Engine Options,Perkins 404F-22T Engine ..................... 179
Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness ..... 180
Electrical Schematic - Engine Options, Perkins 804D Engine ........................... 183
Electrical Schematic - Engine Options, Continental TME27 Engine ................. 184
Electrical Schematic - Engine Options, GM 3.0 Engine..................................... 187
Electrical Schematic - Safety Circuits ................................................................ 190
Electrical Schematic - Generator Options .......................................................... 191
Electrical Schematic - Welder Generator Option ............................................... 194
Electrical Schematic - Hydraulic Generator Options .......................................... 195
Hydraulic Schematics ...................................................................................... 197
Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer) ............................ 198
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer) ............................ 199
Electrical Schematic – (from Z8013-4592 to Z8015-5653) ................................ 201
Electrical Schematic – (from Z8015-5654) ........................................................ 201
xii
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Section 2
Specific ati ons
Machine Specifications
Performance Specifications
Tires and wheels
Drive speed, maximum
(models with rough terrain tires)
Tire size
(foam filled and non-marking)
18-625 FF
Tire size
(Hi-flotation)
445D50/70
Stowed position
Raised or extended
Tire ply rating
(foam filled and non-marking)
Tire weight, new foam-filled (minimum)
(Rough terrain)
16
622 lbs
282 kg
Tire ply rating
(Hi-flotation)
Stowed position
Raised or extended
40.7 in
103.3 cm
Overall tire diameter
(Hi-flotation)
45.47 in
115.5 cm
40 ft / 40 - 45 sec
12.2 m / 40 - 45 sec
Drive speed, maximum
(models with Hi-flotation tires)
14
Overall tire diameter
(foam filled and non-marking)
40 ft / 8.7 - 9.3 sec
12.2 m / 8.7 - 9.3 sec
40 ft / 13.6 - 14.5 sec
12.2 m / 13.6 - 14.5 sec
40 ft / 62 - 70 sec
12.2 m / 62 - 70 sec
Braking distance, maximum
High range on paved surface
6 ft
1.8 m
Wheel diameter
(foam filled and non-marking)
24.5 in
62.2 cm
Gradeability
Wheel diameter
(Hi-flotation)
28 in
71.1 cm
Boom function speeds, maximum from platform
controls
Wheel width
(foam filled, non-marking and Hi-flotation)
15 in
38.1 cm
Jib boom up
23 to 33 seconds
Jib boom down
21 to 31 seconds
Primary boom up, retracted
-35° to 65°
60 to 70 seconds
Primary boom down, retracted
-35° to 65°
75 to 85 seconds
Secondary boom up
38 to 48 seconds
Secondary boom down
38 to 48 seconds
Primary boom extend
48 to 52 seconds
Primary boom retract
38 to 42 seconds
Platform Rotate 160°
10 to 14 seconds
Tire Pressure (Hi-flotation)
Wheel lugs
80 lbs
5.5 bar
11 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
570 Nm
Lug nut torque, lubricated
320 ft-lbs
434 Nm
Fluid capacities
Fuel tank
LPG tank
35 gallons
132.5 liters
33.5 lbs
15.2 kg
See Operator's
Manual
Turntable rotate, 360° boom fully
retracted
114 to 126 seconds
200 to 240 seconds
Hydraulic tank
45 gallons
170 liters
Turntable rotate, 360° boom
extended
Hydraulic system (including tank)
80 gallons
303 liters
For operational specifications, refer to the
Operator's Manual.
Drive hubs, 2WD
Drive hubs, 4WD
Turntable rotation drive hub
30.5 fl oz
902 cc
23 fl oz
680 cc
40 fl oz
1183 cc
Drive hub oil type: SAE 90 multipurpose hypoid gear oil API
service classification GL5
Part No. 1268556
1
Service and Repair Manual
September 2016
Specifications
Hydraulic Oil Specifications
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 ppm
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Hydraulic Fluid Temperature
Range
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV 46
Fire resistant
UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
Support before use.
Optional fluids may not have the
same hydraulic lifespan and
may result in component
damage.
Ambient air temperature
1
2
3
4
Chevron hydraulic oil 5606A
Petro-Canada Environ MV 46
UCON Hydrolube HP-5046D
Chevron Rando HD premium oil MV
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
2
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Petro-Canada Environ MV 46
Fluid Properties
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
ISO Grade
46
Viscosity index
200
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Brookfield Viscosity
cP @ -4°F / -20°C
cP @ -22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Flash point
482°F / 250°C
Pour point
-49°F / -45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Chevron 5606A Hydraulic Oil
Fluid Properties
Brookfield Viscosity
cSt @ -4°F / -20°C
cSt @ -13°F / -25°C
cSt @ -40°F / -40°C
481
702.4
2624
15
Flash point
>100
300
Pour point
-76°F / -60°C
Maximum continuous operating
temperature
103°F / 75°C
ISO Grade
Viscosity index
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @ -40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Part No. 1268556
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
Viscosity index
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F / -18°C
Flash point
46
192
22
46
1300
None
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
189°F / 87°C
3
Service and Repair Manual
September 2016
Specifications
Hydraulic Component
Specifications
Function manifold
Drive Pump
Primary boom down relief valve pressure
(measured at LS port)
1300 psi
89.6 bar
Secondary boom down relief pressure
(measured at LS port)
2500 psi
172 bar
Secondary boom up relief pressure
(measured at LS port)
2500 psi
172 bar
Primary boom extend relief pressure
(measured at LS port)
1300 psi
89.6 bar
Secondary boom extend relief pressure
(measured at LS port)
2600 psi
179 bar
Platform manifold relief pressure
3000 psi
207 bar
System relief valve pressure, maximum
(measured at PTEST port)
Type: bi-directional variable displacement piston pump
Displacement per revolution
Flow rate @ 2300 rpm
Drive pressure, maximum
2.8 cu in
46 cc
28 gpm
106 L/min
3625 psi
250 bar
Charge Pump
Type
Displacement per revolution
Flow rate @ 2300 rpm
gerotor
0.85 cu in
13.9 cc
9 gpm
34 L/min
Charge pressure @ 2300 rpm
Neutral position
320 psi
22 bar
Function pump
Flow rate @ 2300 rpm
Displacement per revolution
Pump 2 (outer)
Flow rate @ 2300 rpm
3 gpm
11.4 L/min
Oscillate manifold
Oscillate relief pressure (item BE or CH)
1.94 cu in
31.8 cc
17 gpm
64 L/min
0.58 cu in
9.5 cc
5 gpm
19 L/min
Hot oil relief pressure
280 psi
19.3 bar
Brakes
Brake relief pressure
240 psi
16.5 bar
Hydraulic Filters
Beta 3 ≥ 200
High pressure filter:
High pressure filter bypass pressure
102 psi
7 bar
Auxiliary Pump
Beta 3 ≥ 200
Type: two-section fixed displacement gear pump
Medium pressure filter
Displacement per revolution
Section 1 (inner)
Medium pressure filter bypass pressure
Flow rate @ 2687 rpm
Displacement per revolution
Section 2 (outer)
Flow rate @ 2687 rpm
4
800 psi
55.1 bar
Drive manifold
Type: two-section tandem gear pump
Displacement per revolution
Pump 1 (inner)
Platform manifold flow regulator
3200 psi
220.6 bar
0.159 cu in
2.61 cc
1.7 gpm
6.4 L/min
Hydraulic tank return filter
51 psi
3.5 bar
10 micron
with 25 psi / 1.7 bar bypass
0.051 cu in
0.84 cc
0.3 gpm
1.1 L/min
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Manifold Component Specifications
Valve coil resistance specifications
Plug torque
Proportional solenoid valve, 12V DC
(schematic items G, W and AB)
4.8Ω
Proportional solenoid valve, 12V DC
(schematic items R)
9Ω
3 position 4 way solenoid valve, 12V DC
(schematic items BA, BB, CA, CB, CP, CQ,
GB, GP and GQ)
9Ω
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51 Nm
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm
3 position 4 way solenoid valve, 10V DC
(schematic items O and S)
6.3Ω
2 position 2 way solenoid valve, 10V DC
(schematic items J)
3.3Ω
2 position 2 way solenoid valve, 10V DC
(schematic items C and P)
6.3Ω
2 position 3 way solenoid valve, 10V DC
(schematic items H, V, X, Z, AA, EE and EF)
6.3Ω
2 position 3 way solenoid valve, 12V DC
(schematic items BC, BD, CE, CF, FB and FC)
9Ω
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Part No. 1268556
5
Service and Repair Manual
September 2016
Specifications
Continental TME27 Engine
Displacement
Oil Pressure switch
164 cu. in
2.68 liters
Number of cylinders
Bore and Stroke
Horsepower, continuous
@ 2500 rpm
Firing order
4
3.58 x 4.06 inches
91 x 103.2 mm
59 hp / 43.9 kW
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
7 psi
0.55 bar
Fuel pump
Fuel pressure
39-40 psi
2.7 bar
Fuel flow rate
0.42 gpm
1.59 L/min
1-3-4-2
Standby idle-computer
controlled Frequency
1000 rpm
Fuel requirement
Low function idle-computer
controlled Frequency
1500 rpm
For fuel requirements, refer to the engine Operator
Manual for your engine.
53.33 Hz
High function idle-computer
controlled Frequency
2500 rpm
8.2:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
Current draw, normal load
Cranking speed
83.33 Hz
Compression ratio
Starter motor
electronic
Battery – Engine starting and control system
Type
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
Intake
0.014 in
0.36 mm
Exhaust
0.018 in
0.45 mm
Capacity
(engine only)
2
1000A
200 Minutes
40 to 60 psi
2.8 to 4.1 bar
7 quarts
6.6 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
10.7 quarts
10.1 liters
Coolant temperature switch
Installation torque
Lubrication system
Oil capacity (including filter)
12V DC, Group 31
Engine coolant
Valve clearance, warm
Oil pressure, hot
150-345A
200 - 250 rpm
Temperature switch point
Alternator output
Fan belt deflection
8 - 18 ft-lbs
11 - 24 Nm
230°F
110°C
65A @ 13.8V DC
1/2 inch
12 mm
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
6
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
GM 3.0L Engine
Displacement
Fuel requirement
183 cu. in
3.0 liters
Number of cylinders
Bore and Stroke
Horsepower @ 2500 rpm
Horsepower @ 1500 rpm
Firing order
Standby idle-computer
controlled Frequency
4
4.0 x 3.6 inches
101.6 x 91.44 mm
70 hp / 52 kW
40 hp / 30kW
1-3-4-2
1000 rpm
Low function idle-computer
controlled
1500 rpm
High function idle-computer
controlled
2500 rpm
Compression ratio
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery – Engine starting and control system
Type
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
12V DC, Group 31
2
1000A
200 Minutes
Engine coolant
Capacity
Alternator output
Fan belt deflection
12 quarts
11.4 liters
70A @ 12V DC
1/2 inch
12 mm
9.25:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Lubrication system
Oil pressure, hot
minimum @ 1000 rpm
Oil capacity (including filter)
6 psi
0.4 bar
5 quarts
4.7 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 5W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Part No. 1268556
7
Service and Repair Manual
September 2016
Specifications
Deutz TD2011L04i Engine
Displacement
Oil temperature switch
220.9 cu. in
3.62 liters
Number of cylinders
Bore and Stroke
Horsepower net intermittent @
2400 rpm
Induction system
Firing order
4
3.78 x 4.92 inches
96 x 125 mm
74 hp
55 kW
Installation torque
Temperature switch point
275°F
135°C
Oil Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
22 psi
1.5 bar
turbocharged
1-3-4-2
Fuel injection system
Low idle
1500 rpm
383 Hz
Injection pump pressure, maximum
High idle
2350 rpm
599 Hz
Injector opening pressure
Compression ratio
8 - 18 ft-lbs
11 - 24 Nm
17.5:1
Motorpal
15,000 psi
1034 bar
3046 psi
210 bar
Fuel requirement
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
For fuel requirements, refer to the engine Operator
Manual for your engine.
Governor
Current draw, normal load
centrifugal
mechanical
Cranking speed
Valve Clearance, cold
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm)
Oil capacity (including filter)
Starter motor
12.8 quarts
12.1 liters
250 - 350 rpm
Battery – Engine starting and control system
Type
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
40 to 60 psi
2.8 to 4.1 bar
140 - 200A
Alternator output
Fan belt deflection
12V DC, Group 31
2
1000A
200 Minutes
80A @ 14V DC
3/8 to 1/2 inch
9 to 12 mm
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
8
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Deutz TD 2.9 Engine
Displacement
Oil temperature switch
177 cu. in
2.9 liters
Number of cylinders
Bore and Stroke
Horsepower net intermittent @
2600 rpm
Induction system
Firing order
4
3.6 x 4.3 inches
92 x 110 mm
74.2 hp
55 kW
1-3-4-2
1000 rpm
Low idle
1500 rpm
High idle
2500 rpm
17.4:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
275°F
135°C
Oil Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
20 psi
1.4 bar
Fuel injection system
Injection pump pressure, maximum
Motorpal
15,000 psi
1034 bar
Injector opening pressure
3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Brush length, new
250 - 400A
0.72 in
18.5 mm
Brush length, minimum
0.27 in
7 mm
Battery – Engine starting and control system
Lubrication system
Oil capacity (including filter)
Temperature switch point
Current draw, normal load
Valve Clearance, cold
Oil pressure, hot (@ 2000 rpm)
8 - 18 ft-lbs
11 - 24 Nm
turbocharged
Standby idle
Compression ratio
Installation torque
40 to 60 psi
2.8 to 4.1 bar
9.4 quarts
9 liters
Oil viscosity requirements
Type
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
Alternator output
-22°F to 86°F / -30°C to 30°C
5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Fan belt deflection
12V DC, Group 31
2
1000A
200 Minutes
95A @ 14V DC
3/8 to 1/2 inch
9 to 12 mm
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Part No. 1268556
9
Service and Repair Manual
September 2016
Specifications
Perkins 404F-22T
Displacement
Oil Pressure switch
134 cu. in
2.2 liters
Number of cylinders
Bore and Stroke
Horsepower net
intermittent @ 2800 rpm
Induction system
4
3.31 x 3.94 inches
84 x 100 mm
55 hp
41.1 kW
turbocharged
Installation torque
Pressure switch point
8 - 18 ft-lbs
11 - 24 Nm
14.2 psi
1 bar
Fuel injection system
Injection pump make
Injection pressure
Zexel
2133 psi
147 bar
Fuel requirement
Firing order
1-3-4-2
Standy idle
1100 rpm
For fuel requirements, refer to the engine Operator
Manual for your engine.
Low idle
1500 rpm
Starter motor
High idle
2500 rpm
Current draw, normal load
Compression ratio
23.3:1
140A - 200A
Brush length, new
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
0.7480 in
199 mm
Brush length, minimum
0.5 in
12.7 mm
Governor
Battery
electronic
Type
Valve Clearance, cold
Intake
Exhaust
0.008 in
0.2 mm
0.018 in
0.45 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm)
Oil capacity (including filter)
Quantity
Battery capacity, maximum
Reserve capacity @ 25A rate
9.4 - 11.2 quarts
8.9 - 10.6 liters
Oil viscosity requirements
5W-20 CJ4
-4°F to 104°F / -20°C to 40°C
10W-40 CJ4
Above 5°F / -15°C
15W-40 CJ4
200 Minutes
14 quarts
13.3 liters
Coolant temperature switch
Installation torque
Temperature switch point
-22°F to 86°F / -30°C to 30°C
2
1000A
Engine coolant
Capacity
40 to 60 psi
2.8 to 4.1 bar
12V DC, Group 31
8 - 18 ft-lbs
11 - 24 Nm
221°F
105°C
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
10
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Perkins 804D-33
Displacement
Injection system
201 cu. in
3.3 liters
Number of cylinders
Bore and Stroke
4
3.70 x 4.72 inches
94 x 120 mm
Horsepower
63 @ 2600 rpm
47 KW @ 2600 rpm
Firing order
1-3-4-2
Compression ratio
Compression pressure
22:1
300 to 500 psi
20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must be
within 50 psi / 3.45 bar of highest cylinder
Injection pump make
Injection pump pressure
Injector opening pressure
~2000 psi
~138 bar
For fuel requirements, refer to the engine Operator
Manual for your engine.
Engine coolant
Capacity
12.5 quarts
11.8 liters
Batteries
Type
1650 rpm
335.5 Hz
Group
Low idle with generator
Frequency
1400 rpm
284.7 Hz
Cold cranking ampere
High idle
Frequency
2300 rpm
467.7 Hz
Alternator output
mechanical all speed
1707 to 1849 psi
117.7 to 127.5 bar
Fuel requirement
Low idle
Frequency
Governor
Zexel
Quantity
Reserve capacity @ 25A rate
Fan belt deflection
12V DC
31
2
1000A
200 minutes
90A @ 12V DC
3/8 to 1/2 inch
9 to 12 mm
Valve Clearance, cold
Intake
0.0098 in
0.25 mm
Exhaust
0.0098 in
0.25 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm)
Oil capacity (including filter)
40 to 60 psi
2.8 to 4.1 bar
10.6 quarts
10 liters
Oil viscosity requirements
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Part No. 1268556
11
Service and Repair Manual
September 2016
Specifications
Machine Torque Specifications
Platform Rotator
1-8 center bolt, GR 5, dry
(before SN 15-5630)
640 ft-lbs
867 Nm
1-8 center bolt, GR 5, dull gray
(from SN 15-5630)
615 ft-lbs
834 Nm
3/8 -16 bolts, GR 8
*(use blue thread locking compound)
35 ft-lbs*
47.5 Nm*
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
Rotate drive hub mounting bolts, lubricated
Backlash plate mounting bolts, lubricated
180 ft-lbs
244 Nm
80 ft-lbs
108 Nm
280 ft-lbs
379 Nm
Drive motors and hubs
Drive hub mounting bolts, lubricated
160 ft-lbs
217 Nm*
Drive hub mounting bolts, dry
210 ft-lbs
284 Nm
Drive motor mounting bolts, dry
110 ft-lbs
149 Nm
Drive motor mounting bolts, lubricated
*(use blue thread locking compound)
Drive motor mounting bolts, dry
Drive hub oil plug, O-ring seal
12
80 ft-lbs*
108.4 Nm*
110 ft-lbs
149 Nm
13 ft-lbs
18 Nm
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
Hydraulic Hose and Fitting
Torque Specifications
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be
torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.
SAE Dash Size
Torque
-4
14 ft-lbs / 19 Nm
-6
23 ft-lbs / 31.2 Nm
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size
Torque
-4
10 ft-lbs / 13.6 Nm
-6
30 ft-lbs / 40.7 Nm
-8
40 ft-lbs / 54.2 Nm
-10
60 ft-lbs / 81.3 Nm
-12
85 ft-lbs / 115 Nm
-16
110 ft-lbs / 150 Nm
-20
140 ft-lbs / 190 Nm
-24
180 ft-lbs / 245 Nm
-8
36 ft-lbs / 54.2 Nm
-10
62 ft-lbs / 84 Nm
-12
84 ft-lbs / 114 Nm
-16
125 ft-lbs / 169.5 Nm
-20
151 ft-lbs / 204.7 Nm
-24
184 ft-lbs / 249.5 Nm
Adjustable Fitting
Non-adjustable fitting
1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size
Thread Size
Flats
-4
7/16-20
2
-6
9/16-18
1¼
-8
3/4-16
1
-10
7/8-14
1
-12
1 1/16-12
1
-16
1 5/16-12
1
-20
1 5/8-12
1
-24
1 7/8-12
1
Part No. 1268556
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size
Torque
-4
ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-6
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
-10
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
-12
(All types)
135 ft-lbs / 183 Nm
-16
(All types)
200 ft-lbs / 271.2 Nm
-20
(All types)
250 ft-lbs / 339 Nm
-24
(All types)
305 ft-lbs / 413.5 Nm
13
Service and Repair Manual
September 2016
Specifications
Torque Procedure
JIC 37° fittings
1
Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4 Nm.
2
Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
fitting. Refer to Illustration 1.
Seal-Lok™ fittings
1
Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2
Lubricate the O-ring before installation.
3
Be sure the O-ring face seal is seated and
retained properly.
4
Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut finger
tight.
5
Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in
this section.
6
Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
14
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting
Part No. 1268556
September 2016
Service and Repair Manual
Specifications
3
Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the proper
tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4
Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the
body hex fitting.
5
Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Part No. 1268556
15
Service and Repair Manual
September 2016
Specifications
16
Part No. 1268556
September 2016
Service and Repair Manual
Repair Procedures
Section 3
Repair Pr oc edures
Machine Configuration:
 Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
Observe and Obey:
 Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
 Immediately tag and remove from service a
damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Part No. 1268556
17
Service and Repair Manual
September 2016
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point where
repairs can be completed. Then to re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
18
Part No. 1268556
September 2016
Service and Repair Manual
Platform Controls
Platform Controls
The platform controls contains two printed circuit
boards:
The LED circuit board is mounted to the underside
of the control box lid which contains the LEDs. The
LED circuit board sends the input from the operator
to the platform controls circuit board (PCON). The
circuit board (PCON) sends the data to the
turntable control box (TCON) for processing.
The platform controls ECM circuit board
communicates with the turntable controls. The
joystick controllers at the platform controls utilize
Hall Effect technology and require no adjustment.
The operating parameters of the joysticks are
stored in memory at the turntable controls. If a
joystick controller error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. Refer to
Repair Procedure, How to Calibrate a Joystick
Controller.
Each joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
1 platform controls ALC-1000 circuit board
2 primary boom extend/retractjoystick
3 secondary boom up/extend
anddown/retract joystick
4 drive/steer joystick controller
5 LED circuit board
6 primary boom up/down and turntable rotate
left/right joystick
For further information or assistance, consult Genie
Product Support.
Part No. 1268556
19
Service and Repair Manual
September 2016
Platform Controls
1-1
Platform Circuit Board
7
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
Note: When the platform circuit board is replaced,
the joystick controllers will need to be calibrated.
Refer to Repair Procedure, How to Calibrate a
Joystick.
How to Remove the Circuit Board
1
2
Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
Locate the cables that connect to the bottom of
the control box. Number each cable and its
location at the control box.
3
Disconnect the cables from the bottom of the
platform control box.
4
Remove the control cable receptacle retaining
fasteners from the bottom of the platform
control box.
5
Remove the platform control box lid retaining
fasteners. Open the control box lid.
6
Locate the circuit board mounted to the inside
of the platform control box.
20
Attach a grounded wrist strap to the ground
screw inside the control box.
8
Tag and carefully disconnect the wire
connectors from the circuit board.
9
Tag and disconnect the ribbon cable from the
LED circuit board.
10 Remove the circuit board mounting fasteners.
11 Carefully remove the circuit board from the
control box.
Part No. 1268556
September 2016
Service and Repair Manual
Platform Controls
How to R emove the LED Circui t Board
How to Remove the LED Circuit
Board
1
Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2
Remove the platform control box lid retaining
fasteners. Open the control box lid.
3
Locate the circuit board mounted to the inside
of the platform control box.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
4
Tag and carefully disconnect the ribbon cables
from the membrane circuit board.
5
Remove the circuit board mounting fasteners.
6
Carefully remove the LED circuit board from
the platform control box lid. Do not lose the
plastic spacers.
1-2
Joysticks
How to Calibrate a Joystick
The joystick controllers on this machine utilize
digital Hall Effect technology for proportional control.
If a joystick controller is disconnected or replaced, it
must be calibrated before that particular machine
function will operate.
Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set.
Note: After each joystick is calibrated, check the
display at the ground control box. There should be
no calibration faults shown on the display. If
calibration faults exist, repeat procedure for that
joystick controlled function.
Note: Perform this procedure with the engine off.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus
Minus
Previous
Enter
Note: When installing the LED circuit board, be sure
the plastic spacers are installed between the circuit
board and the control box lid.
Part No. 1268556
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Service and Repair Manual
September 2016
Platform Controls
Drive functions:
Steer functions:
1
Turn the key switch to the off position.
1
Turn the key switch to the off position.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Press the minus button twice, then press the
enter button twice.
3
Press the minus button twice, then press the
enter button twice.
4
Use the scroll button to scroll through the
menu until DELETE DRIVE JOYSTICK
DEFAULTS is displayed.
4
Use the scroll button to scroll through the
menu until DELETE STEER JOYSTICK
DEFAULTS is displayed.
5
Press the plus button to select YES, then
press the enter button.
5
Press the plus button to select YES, then
press the enter button.
6
Do not start the engine.
6
Do not start the engine.
7
Locate the drive/steer joystick.
7
Locate the drive/steer joystick.
8
Move the drive/steer joystick full stroke in the
forward direction and hold for 5 seconds, then
return to the center or neutral position.
8
9
Move the drive/steer joystick full stroke in the
reverse direction and hold for 5 seconds, then
return to the center or neutral position.
Move the drive/steer joystick or thumb rocker
switch (if equipped) full stroke in the left
direction and hold for 5 seconds, then return to
the center or neutral position.
9
Move the drive/steer joystick or thumb rocker
switch (if equipped) full stroke in the right
direction and hold for 5 seconds, then return to
the center or neutral position.
Result: The alarm at the ground controls
should sound for a successful calibration.
Result: The alarm at the ground controls
should sound for a successful calibration.
22
Part No. 1268556
September 2016
Service and Repair Manual
Platform Controls
Secondary boom up/down and extend/retract
functions:
Primary boom extend/retract functions:
1
Turn the key switch to the off position.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Press the minus button twice, then press the
enter button twice.
4
Use the scroll button to scroll through the
menu until DELETE PRIMARY BOOM
EXTEND/RETRACT JOYSTICK DEFAULTS
is displayed.
Press the plus button to select YES, then
press the enter button.
5
Press the plus button to select YES, then
press the enter button.
6
Do not start the engine.
6
Do not start the engine.
7
Locate the secondary boom up/down and
extend/retract joystick.
7
Locate the thumb rocker switch on top of the
primary boom/turntable rotate joystick.
8
Move the secondary boom up/down and
extend/retract joystick full stroke in the
up/extend direction and hold for 5 seconds,
then return to the center or neutral position.
8
Move the primary boom extend/retract thumb
rocker switch full stroke in the extend direction
and hold for 5 seconds, then return to
thecenter or neutral position.
9
Move the secondary boom up/down and
extend/retract joystick full stroke in the
down/retract direction and hold for 5 seconds,
then return to the center or neutral position.
9
Move the primary boom extend/retract thumb
rocker switch full stroke in the retract direction
and hold for 5 seconds, then return to the
center or neutral position.
1
Turn the key switch to the off position.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Press the minus button twice, then press the
enter button twice.
4
Use the scroll button to scroll through the
menu until DELETE SECONDARY BOOM
JOYSTICK DEFAULTS is displayed.
5
Result: The alarm at the ground controls
should sound for a successful calibration.
Part No. 1268556
Result: The alarm at the ground controls
should sound for a successful calibration.
23
Service and Repair Manual
September 2016
Platform Controls
Primary boom up/down functions:
Turntable rotate functions:
1
Turn the key switch to the off position.
1
Turn the key switch to the off position.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Press the minus button twice, then press the
enter button twice.
3
Press the minus button twice, then press the
enter button twice.
4
Use the scroll button to scroll through the
menu until DELETE PRIMARY BOOM
UP/DOWN JOYSTICK DEFAULTS is
displayed.
4
Use the scroll button to scroll through the
menu until DELETE TURNTABLE ROTATE
JOYSTICK DEFAULTS is displayed.
5
5
Press the plus button to select YES, then
press the enter button.
Press the plus button to select YES, then
press the enter button.
6
Do not start the engine.
6
Do not start the engine.
7
7
Locate the primary boom/turntable rotate
joystick.
Locate the primary boom/turntable rotate
joystick.
8
8
Move the boom/turntable rotate joystick full
stroke in the up direction and hold for
5 seconds, then return to the center or neutral
position.
Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then
return to the center or neutral position.
9
Move the boom/turntable joystick full stroke in
the right direction and hold for 5 seconds, then
return to the center or neutral position.
9
Move the boom/turntable rotate joystick full
stroke in the down direction and hold for
5 seconds, then return to the center or neutral
position.
Result: The alarm at the ground controls
should sound for a successful calibration.
Result: The alarm at the ground controls
should sound for a successful calibration.
24
Part No. 1268556
September 2016
Service and Repair Manual
Platform Controls
How to R es et a Proportional Val ve Coil D efault
How to Set the F unction T hresholds and D efault Func tions Speeds
How to Reset a Proportional Valve
Coil Default
How to Set the Function
Thresholds and Default Functions
Speeds
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus
Minus
Previous
Enter
Note: This procedure only needs to be performed if
a proportional valve has been replaced.
Note: After the valve coil defaults have been set,
each machine function threshold and default
function speed must be set. Refer to Repair
Procedure, How to Set the Function Thresholds
and Default Function Speeds.
Note: Before the threshold and default function
speeds can be set, the boom function proportional
valve coil defaults must be set first. Refer to Repair
Procedure, How to Reset a Proportional Valve Coil
Default.
Note: If a boom function proportional valve coil has
not been replaced and just want to reset the
function speed to original factory settings, proceed
to Function speeds procedure.
1
Start the engine from the platform controls.
2
Press down the foot switch.
Note: Be sure the engine rpm is set to foot switch
activated high idle.
1
Turn the key switch to the off position.
Function threshold:
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Select a joystick controlled function that needs
to have the threshold set.
4
Slowly move the joystick off center in either
direction just until the machine function starts
to move, then move the joystick very slowly
towards the neutral or center position just
before the machine function stops. Do not let
go of the joystick.
5
While holding the joystick in position, press the
engine start button at the platform controls to
set the joystick controller threshold.
3
Press the minus button twice, then press the
enter button twice.
4
Use the previous button to scroll through the
menu until the function valve that needs to be
reset is displayed. Press the plus button to
select yes, then press the enter button to save
the setting.
5
Press the enter or previous button on the
LCD screen until EXIT is displayed.
6
Press the plus button or minus button to
select YES and then press the enter button.
Part No. 1268556
25
Service and Repair Manual
September 2016
Platform Controls
6
7
8
Slowly move the joystick off center in the
opposite direction just until the machine
function starts to move, then move the joystick
very slowly towards the neutral or center
position just before the machine function
stops. Do not let go of the joystick.
While holding the joystick in position, press the
engine start button at the platform controls to
set the joystick controller threshold.
Repeat steps for each joystick controlled
machine function:
• Primary boom up/down
• Turntable rotate left/right
• Primary boom extend/retract
• Secondary up/down and extend/retract
• Drive forward/reverse
9
Once the threshold has been set, press and
hold the engine start button until the engine
shuts off. Do not press the red Emergency
Stop button.
Note: Approximately 3 seconds after the engine
shuts off, the alarm at the ground controls will
sound to indicate the settings are being saved in
memory.
10 At the ground controls, turn the key switch to
the off position, wait a moment and then turn
the key switch to platform controls.
11 Check the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.
26
Function speeds:
Note: Be sure the machine is in the stowed position
and the boom is rotated between the circle end
tires.
Note: Perform this procedure with the machine on a
firm, level surface that is free of obstructions.
Note: Unless the LCD screen displays NOT
CALIBRATED, it will be necessary to enter the
valve calibration menu.
12 Start the engine from the platform controls.
13 Select a function that needs the function speed
set.
14 Boom up/down functions: Move the joystick
full stroke in the up direction. When the alarm
sounds, move the joystick in the opposite
direction full stroke until the alarm sounds
again. Return the joystick to center.
Boom extend/retract functions: Raise the
primary boom until it no longer rests on the
boom cradle. Then move the joystick full stroke
in the extend direction. When the alarm
sounds, move the joystick in the opposite
direction full stroke until the alarm sounds
again. Return the joystick to center.
Turntable rotate functions: Raise the
primary boom until it no longer rests on the
boom cradle. Move the joystick full stroke in
either the left or right direction until a drive
enable zone is reached. Move the joystick in
the opposite direction full stroke until the alarm
sounds. Now move the joystick in the opposite
direction full stroke until the alarm sounds
again. Return the joystick to center.
Part No. 1268556
September 2016
Service and Repair Manual
Platform Controls
How to Adj ust the Functi on Speeds
15 Once the function speeds have been set,
press and hold the engine start button until the
engine shuts off. Do not press the red
Emergency Stop button.
Note: Approximately 3 seconds after the engine
shuts off, the alarm at the ground controls will
sound to indicate the settings are being saved in
memory.
How to Adjust the Function
Speeds
Note: Perform this procedure with the boom in the
stowed position.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
16 At the ground controls, turn the key switch to
the off position, wait a moment and then turn
the key switch to platform controls.
17 Check the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.
Part No. 1268556
Plus
Minus
Previous
Enter
1
Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
3
Press the plus button twice, then press the
minus button twice.
4
Press the previous button until the function to
be adjusted is displayed.
5
Press the plus button to increase the speed or
press the minus button to decrease the speed.
27
Service and Repair Manual
September 2016
Platform Components
6
Press the enter button to save the setting in
memory.
4
Press the previous button until the function to
be adjusted is displayed.
7
Press the enter or previous button on the
LCD screen until EXIT is displayed.
5
8
Press the plus button or minus button to
select YES and then press the enter button.
Press the plus button to increase the ramp
rate or press the minus button to decrease the
ramp rate.
6
Press the enter button to save the setting in
memory.
7
Press the enter or previous button on the
LCD screen until EXIT is displayed.
8
Press the plus button or minus button to
select YES and then press the enter button.
9
Continue to perform this procedure until the
machine function speed meets specification.
Refer to Specifications, Performance
Specifications.
How to Adj ust the Functi on R amp R ate Setti ng
How to Adjust the Function Ramp
Rate Setting
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum
output, when moved out of the neutral position. The
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain
peak performance from the machine.
Note: Perform this procedure with the boom in the
stowed position.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Ramp Rate Specifications
Ramp rate (factory settings)
Turntable rotate
accelerate
4 seconds
decelerate
1.0 second
Primary boom up/down
accelerate
3 seconds
decelerate
0.25 second
Primary boom extend/retract
accelerate
3 seconds
decelerate
0.75 second
Secondary boom up/down
Plus
1
2
3
28
Minus
Previous
Enter
Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
Press the plus button twice, then press the
previous button twice.
accelerate
7 seconds
decelerate
0.75 second
Secondary boom extend/retract
accelerate
7 seconds
decelerate
0.75 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
1.5 seconds
0.5 second
0.5 second
0.75 second
2 seconds
decelerate, shift from low to high
speed
1 second
decelerate, shift from high to low
speed
4 seconds
Part No. 1268556
September 2016
Service and Repair Manual
Platform Components
2-1
Platform
2-2
Platform Leveling Cylinder
How to Remove the Platform
1
Separate the foot switch quick disconnect
plug.
2
Support the platform with an appropriate lifting
device.
3
Locate the cables that connect to the bottom of
the control box. Number each cable and its
location at the platform control box.
4
Disconnect the cables from the bottom of the
platform control box.
5
Remove the platform control box mounting
fasteners. Remove the platform control box
and set it aside.
6
Remove the air line to platform bracket
retaining fasteners (if equipped).
7
Remove the weld cable from the platform (if
equipped).
8
Remove the platform mounting fasteners and
remove the platform from the machine.
Crushing hazard. The platform
mounting weldment may
become unbalanced and fall if it
is not properly supported.
The platform leveling cylinder keeps the platform
level through the entire range of boom motion. The
platform is maintained level to the turntable. To
accomplish this, the ECM at the ground controls
compares the difference in readings between the
platform angle sensor and the turntable level
sensor, which then sends a signal to the platform
controls to open or close the appropriate platform
level proportional valve on the platform manifold to
maintain a level platform. The platform leveling
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.
How to R emove the Pl atfor m Leveling C yli nder
How to Remove the Platform
Leveling Cylinder
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
Extend the boom until the platform leveling
cylinder barrel-end pivot pin is accessible.
2
Raise the jib boom slightly and place blocks
under the platform.
3
Lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
Part No. 1268556
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Service and Repair Manual
September 2016
Platform Components
4
Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder at the
bulkhead fittings located inside the boom tube
at the platform end. Cap the bulkhead fittings
on the boom tube.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5
Remove the pin retaining fasteners from the
platform leveling cylinder rod-end pivot pin. Do
not remove the pin.
6
Remove the external snap rings from the
barrel-end pivot pin. Do not remove the pin.
7
Support and secure the jib boom cylinder to
the jib boom with a strap or other suitable
device. Protect the cylinder rod from damage.
Crushing hazard. The jib boom
cylinder will fall if not properly
supported when the platform
level cylinder rod-end pivot pin is
removed.
8
10 Use a soft metal drift to tap the platform level
cylinder rod-end pivot pin half way out and
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
11 Use a soft metal drift to remove the platform
level cylinder rod-end pivot pin.
12 Carefully pull the platform leveling cylinder out
of the boom.
Crushing hazard. The jib boom
cylinder will fall if not properly
supported when the platform
level cylinder rod-end pivot pin is
removed.
How to Bleed the Pl atfor m Leveli ng C ylinder
How to Bleed the Platform
Leveling Cylinder
Note: Do not start the engine. Use auxiliary power
for this procedure.
1
Raise the jib boom to a horizontal position.
2
Push the platform level up and down buttons
through two complete platform leveling cycles
to remove any air that might be in the system.
Use a soft metal drift to remove the barrel-end
pivot pin.
Crushing hazard. The platform
and jib boom will fall when the
platform leveling cylinder
barrel-end pivot pin is removed if
not properly supported.
9
30
Support the rod end of the platform level
cylinder.
Part No. 1268556
September 2016
Service and Repair Manual
Platform Components
2-3
Platform Rotator
3
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Platform
Rotator
Component damage hazard.
Mark the platform mounting
weldment and the rotator flange
before removing the platform
mounting weldment. The
platform mounting weldment
must be replaced in the exact
same position on the rotator
flange as it was before removal.
If a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
2
Remove the platform. Refer to Repair
Procedure, How to Remove the Platform.
Tag and disconnect the electrical connector
from the platform angle sensor.
Part No. 1268556
Tag, disconnect and plug the hydraulic hoses
from the platform rotator manifold. Cap the
fittings on the manifold.
4
Remove the hose and cable clamp from the
platform support.
5
Remove the platform manifold mounting
fasteners. Lay the platform manifold to the
side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
6
Remove the power to platform electrical outlet
box bracket mounting fasteners.
7
Remove the power to platform electrical outlet
box from the platform and lay it to the side.
8
Remove the weld cable from the platform
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
9
Support the platform mounting weldment, but
do not apply any lifting pressure.
10 Remove the eight mounting bolts from the
platform mounting weldment.
31
Service and Repair Manual
September 2016
Platform Components
How to Bleed the Pl atfor m R otator
11 Remove the center bolt and slide the platform
mounting weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment may
become unbalanced and fall if it
is not properly supported.
How to Bleed the Platform Rotator
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
1
Rotate the platform full right, then full left until
air is completely out of the rotator. Bleeding the
valve is not necessary.
12 Support the platform rotator with a suitable
lifting device. Do not apply any lifting pressure.
13 Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
14 Support the jib boom leveling arms with a
suitable lifting device.
15 Use a soft metal drift to remove both pins and
remove the platform rotator from the machine.
Crushing hazard. The jib boom
leveling arms may fall if they are
not properly supported when the
jib boom leveling arm pivot pin is
removed.
Component damage hazard. The
platform angle sensor is a very
sensitive instrument. It can be
damaged internally if is dropped
or sustains any physical shock,
even if the damage is not visible.
32
Part No. 1268556
September 2016
Service and Repair Manual
Platform Components
2-4
Platform Overload System (if
equipped)
The platform overload system is designed to
prevent the machine from continuing to operate
when the load in the platform exceeds maximum
rated capacity. Refer to the machine serial label for
maximum capacity information.
If maximum platform capacity is exceeded, the
alarm will sound and the platform overload indicator
lights will flash at the platform control and
"PLATFORM OVERLOAD" will display on the LCD
screen at the ground control. The ground and
platform controls will become disabled. Before
normal machine operation can continue, the excess
load will need to be removed from the platform.
If the excess load cannot be removed or if the
operator at the platform controls is unable to correct
the overloaded condition, another person at the
ground controls can operate the machine using
auxiliary power. There will be limited control of
boom functions from the ground controls when
using auxiliary power. Auxiliary power can be used
to correct the overloaded platform condition in order
to resume normal, safe operation of the machine.
How to Calibrate the Platform
Overload System (if equipped)
Proper calibration of the platform overload system
is essential to safe machine operation. Continued
use of an improperly calibrated platform overload
system could result in the system failing to sense an
overloaded platform. The stability of the machine is
compromised and it could tip over.
Note: Perform this procedure with the machine on a
firm, level surface.
1
Turn the key switch to platform control. Start
the engine and level the platform.
2
Determine the maximum platform capacity.
Refer to the machine serial plate.
3
Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4
Using a suitable lifting device, place a test
weight equal to the maximum platform
capacity at the center of the platform floor.
Note: The engine must be turned off to use auxiliary
power.
Note: Software versions 1.03 and lower. All
ground control functions will not operate with
auxiliary control. Refer to Repair Procedure, How to
Determine the Revision Level.
Note: Recovery mode must be used. Refer to
Repair Procedure, Bypass / Recovery Keyswitch.
Note: Software versions 1.04 and higher. All
ground control functions will operate from auxiliary
control. Refer to Repair Procedure, How to
Determine the Revision Level.
Part No. 1268556
33
Service and Repair Manual
September 2016
Platform Components
5
Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to
2 inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Proceed to step 6.
Result: The alarm is sounding. The platform
overload indicator light is flashing at the
platform controls and “PLATFORM
OVERLOAD” should is displayed on the LCD
screen at the ground controls. Slowly tighten
the load spring adjustment nut in a clockwise
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
6
Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to
2 inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds. Proceed to
step 7.
Result: The alarm should be sounding. The
platform overload indicator light should be
flashing at the platform controls and
“PLATFORM OVERLOAD” should be
displayed on the LCD screen at the ground
controls. Repeat this procedure beginning with
step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
34
Part No. 1268556
September 2016
Service and Repair Manual
Platform Components
7
Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to
2 inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Proceed to step 8.
Result: The overload indicator lights are
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
8
Add an additional 10 lb / 4.5 kg test weight to
the platform.
Result: The alarm should be sounding. The
platform overload indicator light should be
flashing at the platform controls and
“PLATFORM OVERLOAD” should be
displayed on the LCD screen at the ground
controls. Proceed to step 9.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Remove the additional 10 lb / 4.5 kg
test weight. Repeat this procedure beginning
with step 6.
9
Test all machine functions from the platform
controls.
Result: All platform control functions should
not operate.
10 Turn the key switch to ground control.
11 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test
weight off the platform floor.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
Part No. 1268556
35
Service and Repair Manual
September 2016
Platform Components
2-5
Platform Overload Recovery
Message (software V2.04 and
later)
If the ground controls LCD screen displays
OVERLOAD RECOVERY, the emergency lowering
system has been used while the platform was
overloaded.
How to Clear the Platform
Overload Recovery Message
Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and
repair of this machine.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus
Minus
Previous
Press the buttons on the ground controls in the
following sequence:
(plus)(minus)(minus)(plus).
4
Press the enter or previous button on the
LCD screen until CLEAR OVERLOAD
RECOVERY is displayed.
5
Press the plus button or the minus button to
select YES. Then press the buttons in the
following sequence:
(plus)(plus)(plus)(minus). and press the
enter button to accept.
Note: The passcode buttons
(plus)(plus)(plus)(minus) must be entered in the
proper sequence before the enter button is
pressed.
6
Press the enter or previous button on the
LCD screen until EXIT is displayed.
7
Press the plus button or minus button to
select YES and then press the enter button.
8
Turn the key switch to the off position.
Enter
1
Turn the key switch to the off position.
2
Press and hold the enter button on the ground
control panel while turning the key switch to
ground controls. Hold the enter button for
approximately 5 seconds.
36
3
Part No. 1268556
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Service and Repair Manual
Jib Boom Components
3-1
Jib Boom
4
Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Jib Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
Remove the platform mounting weldment and
the platform rotator. Refer to Repair
Procedure, How to Remove the Platform
Rotator.
2
Remove the hose and cable cover retaining
fasteners from the jib boom. Remove the hose
and cable cover from the machine.
3
Attach a lifting strap from an overhead crane to
the jib boom for support. Do not apply lifting
pressure.
Part No. 1268556
1
2
3
4
5
6
7
8
jib boom
platform rotator upper pivot pin
platform rotator lower pivot pin
jib boom leveling arm
jib cylinder pivot pin
jib boom cylinder
primary boom lower pivot pin
primary boom upper pivot pin
5
Support the barrel end of the jib boom cylinder
with another suitable lifting device.
6
Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
37
Service and Repair Manual
September 2016
Jib Boom Components
7
Use a soft metal drift to remove the pin and let
the cylinder hang down.
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not
properly supported by the
overhead crane.
8
Secure the jib boom bellcrank to prevent it
from moving.
9
Remove the hose and cable clamp from the jib
boom pivot pin.
10 Remove the pin retaining fastener from the jib
boom pivot pin. Do not remove the pin.
11 Place blocks under the platform leveling
cylinder for support. Protect the cylinder from
damage.
12 Use a soft metal drift to remove the pin.
Carefully remove the jib boom from the primary
boom.
15 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
16 Attach a lifting strap from a second overhead
crane to the jib boom bellcrank.
17 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib
boom lift cylinder and jib boom bellcrank from
the machine.
Crushing hazard. The jib boom
lift cylinder and jib boom
bellcrank could become
unbalanced and fall if not
properly supported when they
are removed from the machine.
Crushing hazard. The platform
leveling cylinder may fall if not
supported when the rod-end
pivot pin is removed.
Crushing hazard. The jib boom
may become unbalanced and fall
when it is removed from the
machine if it is not properly
supported by the overhead
crane.
13 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
14 Slide both of the jib boom leveling arms off of
the jib boom cylinder rod-end pivot pin and lay
them off to the side.
38
Part No. 1268556
September 2016
Service and Repair Manual
Jib Boom Components
3-2
Jib Boom Lift Cylinder
4
How to Remove the Jib Boom Lift
Cylinder
Crushing hazard. The jib boom
lift cylinder may fall if not
supported when the rod-end
pivot pin is removed.
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
5
Support the jib boom lift cylinder with a suitable
lifting device.
6
Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin and let the cylinder hang down.
Raise the jib boom slightly and place blocks
under the platform mounting weldment. Lower
the jib boom until the platform is resting on the
blocks just enough to support the platform.
Crushing hazard. The platform
and jib boom lift cylinder could
become unbalanced and fall if
not properly supported when the
jib boom lift cylinder barrel-end
lift pivot pin is removed.
Note: Do not rest the entire weight of the boom on
the blocks.
2
Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3
Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 1268556
Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out and
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
7
Place blocks under the platform leveling
cylinder for support. Protect the cylinder from
damage.
8
Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib
boom lift cylinder from the machine.
Crushing hazard. The jib boom
lift cylinder may become
unbalanced and fall when it is
removed from the machine if it is
not properly supported by the
overhead crane.
39
Service and Repair Manual
September 2016
Boom Components
1
primary boom link arm pivot pin
13 secondary boom pivot pin
2
primary boom lift cylinder link arm
14 secondary lift cylinder pivot pin - barrel end
3
primary lift cylinder pivot pin - rod end
15 secondary boom lift cylinder
4
primary boom lift cylinder
16 secondary lift cylinder pivot pin - rod end
5
primary lift cylinder pivot pin - barrel end
17 secondary boom
6
primary boom
18 secondary extension boom
7
primary extend cylinder pivot pin - rod end
19 secondary boom hose cover
8
platform level cylinder pivot pin - barrel end
20 secondary extend cylinder pivot pin - rod end
9
primary extension boom
21 secondary boom lever arm pivot pin
10 platform leveling cylinder
22 primary boom lift cylinder lever arm
11 upper turntable cover
23 primary boom pivot pin
12 lower turntable cover
24 primary boom hose cover
25 primary extend cylinder pivot pins - barrel end
40
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
4-1
Primary Boom Cable Track
3
Remove the mounting fasteners from the
power to platform outlet box. Remove the
outlet box and lay to the side.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
4
Remove the hose clamp from the platform
support.
5
Tag and disconnect the electrical connector
from the platform angle sensor.
How to Remove the Primary
Boom Cable Track
Note: The platform angle sensor is mounted to the
platform rotator.
6
Tag and disconnect the electrical connectors
for the foot switch and jib boom limit switch.
7
Remove the platform manifold mounting
fasteners. Remove the manifold and lay to the
side.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the machine on a
firm, level surface.
Note: Perform this procedure with the boom in the
stowed position.
1
Tag and disconnect the wire connectors from
the platform control box.
2
Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold
located on the platform rotator. Cap the fittings
on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 1268556
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
8
Remove the hose and cable cover retaining
fasteners from the jib boom. Remove the hose
and cable cover from the machine.
9
Remove the hose and cable clamp from the jib
boom pivot pin.
The jib boom may fall if not
supported when the jib boom pivot
pin is removed.
10 Tag, disconnect and plug the slave cylinder
hydraulic hoses from the bulkhead fittings at
the platform end of the primary boom. Cap the
bulkhead fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
41
Service and Repair Manual
September 2016
Boom Components
11 Tag, disconnect and plug the jib boom cylinder
hydraulic hoses. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
12 Remove the cotter pin from the platform end of
the cable track tube.
Note: Always replace the cotter pin with a new one
when installing the cable track.
13 Remove the fasteners from the cable track
guide at the platform end of the primary boom.
Remove the cable track guide from the
machine.
18 Tag, disconnect and plug each hydraulic hose
from the bulkhead fittings that lead to the cable
track. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
19 Tag and disconnect each electrical connector
to wiring that leads to the cable track.
20 Pull all hoses and electrical cables through the
opening in the primary boom at the pivot end.
21 Secure the upper and lower cable tracks
together.
22 Attach a lifting strap from an overhead crane to
the cable track.
14 Tag and disconnect the electrical connector
from the limit switch at the pivot end of the
primary boom.
23 Remove all cable track mounting fasteners.
15 Remove all hose clamps for the primary boom
lift cylinder hydraulic hoses.
24 Carefully remove the cable track from the
machine and lay it on a structure capable of
supporting it.
Note: The primary boom lift cylinder hydraulic hose
clamps are located behind the cable track.
16 Support the end cover from the secondary
boom at the pivot end of the primary boom.
17 Remove the cover retaining fasteners and
remove the cover from the machine.
Crushing hazard. The secondary
boom hose cover could become
unbalanced and fall if not
properly supported when
removed from the machine.
42
Component damage hazard. The
boom cable track can be
damaged if it is twisted.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
How to R epair the Primar y Boom C abl e Tr ac k
How to Repair the Primary Boom
Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
6
Remove the upper rollers from the
replacement section of cable track.
7
Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Note: A cable track repair kit is available through
the Genie Service Parts Department.
1
Visually inspect the cable track and determine
which 4-link section needs to be replaced.
2
Support the cable track assembly above the
section to be replaced.
3
Carefully remove the snap rings and pins from
each end of the damaged section of cable
track.
4
Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
track to be replaced. Remove the rollers.
5
Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
track.
8
Connect the ends of the replacement cable
track section to the existing cable track using
the pins and snap rings.
9
Install the rollers onto the new section of cable
track.
10 Operate the primary boom extend/retract
function through a full cycle to ensure smooth
operation of the new section of cable track.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 1268556
43
Service and Repair Manual
September 2016
Boom Components
How to Remove the Primary
Boom
4-2
Primary Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
How to Shi m the Pri mar y Boom
How to Shim the Boom
1
Measure each wear pad.
Result: Each wear pad meets minimum
specification. Proceed to step 2.
Result: Each wear pad does not meet
minimum specification. Replace any wear pad
that does not meet minimum specification.
Proceed to step 2.
2
Extend the boom until the wear pads are
accessible.
3
Loosen the wear pad mounting fasteners.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
4
Install the new shims under the wear pad to
obtain zero clearance and zero drag.
Note: Perform this procedure with the boom in the
stowed position.
5
Tighten the mounting fasteners.
6
Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
binding or scraping.
1
Remove the jib boom. Refer to Repair
Procedure, How to Remove the Jib Boom.
2
Remove the fasteners securing the limit switch
to the primary boom at the pivot end of the
boom. Do not disconnect the wiring. Move the
limit switch to a safe location.
Tag and disconnect the wire harness from the
primary boom angle sensor (PBAS).
Note: Always maintain squareness between the
outer and inner boom tubes.
Primary boom wear pad
specifications
Minimum
3
Top, bottom and side wear pads
(platform end of boom)
0.625 inch
15.9 mm
Note: The primary boom angle sensor is located
inside the primary boom at the pivot end.
Bottom and side wear pads
(pivot end of boom)
0.50 in
12.7 mm
Top wear pads
(pivot end of boom)
0.625 inch
15.9 mm
Secondary boom wear
pad specifications
Minimum
Top, and side wear pads
(extension end of boom)
0.625 inch
15.9 mm
Bottom wear pads (extension
end of boom)
0.50 in
12.7 mm
Top wear pads
(pivot end of boom)
0.50 in
12.7 mm
Bottom and side wear pads
(pivot end of boom)
0.875 in
22.2 mm
44
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
4
Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder. Tag, disconnect and
plug the hydraulic hoses routed through the
primary boom at the union.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5
Attach a lifting strap from an overhead crane to
the barrel end of the primary boom lift cylinder.
6
Remove the pin retaining fasteners from the
primary boom lift cylinder barrel-end pivot pin.
7
Place blocks under both ends of the primary
boom lift cylinder for support.
8
Use a soft metal drift to remove the barrel-end
pivot pin. Rest the barrel end of the primary
boom cylinder on the blocks.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
9
Attach a lifting strap from an overhead crane to
the primary boom lift cylinder linkage arm.
Support the arm.
10 Remove the pin retaining fasteners from the
primary boom lift cylinder linkage arm where it
connects to the primary boom.
Part No. 1268556
11 Use a soft metal drift to remove the upper
primary boom lift cylinder linkage arm pivot pin.
Using a suitable lifting device remove the
linkage arm from the machine.
Crushing hazard. The upper
primary boom lift cylinder linkage
arm will fall if not properly
supported when the pivot pin is
removed.
12 Attach a 5 ton / 5000 kg overhead crane to the
center point of the primary boom.
13 Remove the pin retaining fastener from the
primary boom pivot pin.
14 Use a soft metal drift to remove the primary
boom pivot pin.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
15 Carefully remove the primary boom from the
machine and place it on a structure capable of
supporting it.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when removed from the
machine.
Note: When the primary boom is installed, the
primary boom angle sensor will need to be
calibrated.
45
Service and Repair Manual
September 2016
Boom Components
How to Dis ass embl e the Primar y Boom
How to Disassemble the Primary
Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
4
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
5
Remove the primary boom. Refer to Repair
Procedure, How to Remove the Primary
Boom.
2
Place blocks under the barrel end of the
primary boom extension cylinder for support.
3
Remove the pin retaining fastener from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom.
46
Remove and label the location of the wear
pads from the platform end of the primary
boom.
Note: Pay careful attention to the location and
number of shims used with each wear pad.
6
Attach a lifting strap from an overhead crane to
the extension boom assembly.
7
Support and slide the extension boom
assembly out of the primary boom tube and
place it on a structure capable of supporting it.
Crushing hazard. The extension
boom tube could become
unbalanced and fall if not
properly supported when
removed from the primary boom
tube.
Note: Complete disassembly of the primary boom is
only necessary if the outer or inner primary boom
tube must be replaced. The extension cylinder can
be removed without completely disassembling the
boom. Refer to Repair Procedure, How to Remove
the Primary Boom Extension Cylinder.
1
Use a soft metal drift to remove the pin.
Note: During removal, the overhead crane strap will
need to be adjusted for proper balancing.
8
Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
platform end of the extension tube.
Crushing hazard. The extension
cylinder could become
unbalanced and fall when
removed from primary boom
extension tube if not properly
supported.
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
9
Use a soft metal drift to remove the pin.
Crushing hazard. The extension
cylinder could become
unbalanced and fall when
removed from primary boom
extension tube if not properly
supported.
10 Attach a lifting strap from an overhead crane to
the extension cylinder.
11 Working at the end of the extension boom tube
opposite the jib boom mount, support and slide
the extension cylinder out of the extension
boom tube.
4-3
Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers the
primary boom. The primary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove the Primary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Crushing hazard. The extension
cylinder could become
unbalanced and fall when
removed from primary boom
extension tube if not properly
supported.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the boom in the
stowed position.
Part No. 1268556
1
Raise the primary boom to a horizontal
position.
2
Raise the secondary boom until the primary
boom lift cylinder rod-end pivot pin is above the
counterweight.
3
Attach a 5 ton / 5000 kg overhead crane to the
platform end of the primary boom. Support the
boom. Do not apply any lifting pressure.
4
Support both ends of the primary boom lift
cylinder with a second overhead crane or
similar lifting device.
47
Service and Repair Manual
September 2016
Boom Components
5
Place blocks under the primary boom lift
cylinder linkage arms for support.
6
Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7
Remove the pin retaining fastener from the
primary boom lift cylinder rod-end pivot pin.
8
Use a soft metal drift to remove the pin.
4-4
Primary Boom Extension Cylinder
The primary boom extension cylinder extends and
retracts the primary boom extension tube.The
primary boom extension cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Primary
Boom Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Crushing hazard. The primary
boom will fall if not properly
supported when the pivot pin is
removed.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Crushing hazard. The primary
boom lift cylinder linkage arms
may fall if not properly supported
when the pivot pin is removed.
9
Remove the primary boom lift cylinder
barrel-end pivot pin retaining fasteners.
10 Use a soft metal drift to remove the barrel-end
pivot pin. Remove the primary boom lift
cylinder from the machine.
Crushing hazard. The lift cylinder
will become unbalanced and fall
if not properly supported when
the pin is removed.
48
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the machine on a
firm, level surface and in the stowed position with
the axles extended.
1
Raise the primary boom to a horizontal
position.
2
Extend the primary boom until the primary
boom extension cylinder rod-end pivot pin is
accessible.
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
3
Remove the access cover from the pivot end of
the primary boom.
4
Place blocks under the barrel end of the
primary boom extension cylinder for support.
5
Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
6
Working at the platform end of the boom,
remove the external snap rings from the
extension cylinder rod-end pivot pin.
7
Use a soft metal drift to remove the pin.
Crushing hazard. The primary
boom could fall when removed
from the extension boom if not
properly supported.
8
Remove the barrel-end pivot pin retaining
fasteners.
9
Place a rod through the barrel-end pivot pin
and twist to remove the pin.
Part No. 1268556
10 Working at the pivot end of the boom, support
and slide the extension cylinder out of the
boom extension.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
Component damage hazard. Be
careful not to damage the
primary boom angle sensor
(PBAS) when removing the
cylinder from the primary boom.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
Note: Note the length of the cylinder after removal.
For ease of installation, the cylinder must be at the
same length for installation.
49
Service and Repair Manual
September 2016
Boom Components
4-5
Primary Boom Angle Sensor
A properly functioning primary boom angle sensor
(PBAS) is essential to safe machine operation. The
primary boom angle sensor is used to limit the
angle of the primary boom relative to ground. The
ECM at the ground controls (TCON) monitors the
position and angle of the primary boom using the
signal from PBAS. The PBAS signal is used to
control the ramping of the primary boom as well as
velocity control, limiting the speed of the primary
boom to 1.3 feet / 0.4 meters per second.
6
Remove the angle sensor and bracket
assembly.
7
Remove the sensor retaining fasteners from
the sensor bracket. Remove the angle sensor.
8
Install the new angle sensor onto the mounting
bracket.
9
Install the angle sensor and bracket assembly.
Note: The sensor should be installed rotated in a
fully counter clock-wise position.
10 Insert the threaded rod through the threaded
rod adjustment bracket.
How to R eplac e the Primar y Boom Angle Sensor
How to Replace the Primary
Boom Angle Sensor
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
1
Remove the retaining fasteners from the boom
end cover at the pivot end of the primary boom.
Remove the cover from the machine.
2
Locate the primary boom angle sensor inside
the primary boom at the boom pivot pin.
3
Tag and disconnect the electrical connector
from the sensor.
4
Remove the angle sensor mounting bracket
retaining fasteners.
5
Remove the wing nut from the threaded rod.
Do not disconnect the threaded rod from the
clevis yoke.
50
11 Move the threaded rod to the top of the slotted
hole. Tighten the wing nut and hex nut towards
each other.
12 Connect the electrical connector to the angle
sensor.
13 Calibrate the primary boom angle sensor.
Refer to Repair Procedure, How to Calibrate
the Primary Boom Angle Sensor.
Tip-over hazard. Failure to
calibrate the primary boom
sensor could result in the
machine tipping over resulting
in death or serious injury.
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
How to C alibr ate the Pri mar y Boom Angle Sensor
How to Calibrate the Primary
Boom Angle Sensor
6
Note: A digital level will be required to perform this
procedure.
Loosen the Primary Boom Angle Sensor
(PBAS) assembly bracket fasteners attached
to the primary boom. Loosen the wing nut and
hex nut on the threaded rod to allow the
threaded rod to move upward. Tighten the
fasteners.
7
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Set a digital level on top of the primary boom
mast on a level part of the tube so it is viewable
from the ground controls.
8
Start the engine.
9
Raise the boom until the digital level displays
70°.
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
Plus
1
Minus
Previous
Enter
Pull out the red Emergency Stop button at the
platform controls. From the ground control box,
turn the key switch to ground control and pull
out the red Emergency Stop button while
holding the enter button (3 or 4 seconds) until
the engine symbol appears on the display at
the ground control box, then release.
2
Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
3
Press the previous button until reset primary
boom angle sensor is shown on the display.
4
Press the plus button to select YES, then
press the enter button to accept.
5
Press the previous button until EXIT is shown
on the display. Press the plus button to select
YES, then press and hold the enter button to
accept.
Result: The alarm should sound.
Result: The alarm does not sound. Repeat this
procedure beginning with step 1.
Part No. 1268556
10 Loosen the wing nut from threaded rod and
move the threaded rod down until the engine
turns off.
11 Screw threaded rod into clevis yoke. Tighten
the wing nut to welded bracket. Tighten the
jam nut to welded bracket. Tighten the PBAS
fasteners to boom.
Result: The ground control box display should
read P9B & P11 fault.
12 Push in the red Emergency Stop button to the
off position. Wait until display turns off before
proceeding.
13 Pull out the red Emergency Stop button while
holding the enter button (3 or 4 seconds) until
the engine symbol appears on the display at
the ground control box, then release.
14 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
15 Press the previous button until PRIMARY
BOOM ANGLE = 70° is shown on the display.
16 Press the plus button to select YES, then
press the enter button to accept.
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Service and Repair Manual
September 2016
Boom Components
17 Press the previous button until EXIT is shown
on the display. Press the plus button to select
yes, then press the enter button to accept.
18 At the ground controls, use auxiliary power and
lower the boom until the faults are no longer
shown on the display.
Result: The flashing arrow in the display at the
ground controls will turn off.
Result: The flashing arrow in the display at the
ground controls does not turn off. Repeat this
procedure beginning with step 1.
19 Start the engine and activate the primary boom
down function. Release the function enable
button when the digital level displays 40°. Push
in the red Emergency Stop button to the off
position.
25 Start the engine.
26 Activate the boom up function until the digital
level reads 65°.
Result: The primary boom should stop.
Result: The primary boom does not stop.
Immediately release the function enable button
and lower the boom. Repeat this procedure
beginning with step 1.
Tip-over hazard. If the boom
does not stop at 65°,
immediately release the
function enable button and
lower the primary boom. Failure
to lower the boom could cause
the machine to tip over resulting
in death or serious injury.
20 Pull out the red Emergency Stop button while
holding the enter button (3 or 4 seconds) until
the engine symbol appears on the display at
the ground control box, then release.
21 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
22 Press the previous button until PRIMARY
BOOM ANGLE = 40° is shown on the display.
23 Press the plus button to select YES, then
press the enter button to accept.
Result: The alarm should not sound.
Result: The alarm does sound. Repeat this
procedure beginning with step 1.
24 Press the previous button until EXIT is shown
on the display. Press the plus button to select
yes, then press the enter button to accept.
52
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
4-6
Secondary Boom Cable Track
3
Carefully remove the snap rings and pins from
each end of the damaged section of cable
track.
The secondary boom cable track guides the cables
and hoses running up through the inside of the
secondary boom. It can be repaired link by link
without removing the cables and hoses that run
through it. Removal of the secondary boom cable
track is required to repair it.
4
Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
track to be replaced. Remove the rollers.
5
Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
track.
How to R emove the Secondar y Boom Cabl e Trac k
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
How to Remove the Secondary
Boom Cable Track
Note: The secondary boom cable track must be
removed with the secondary boom extension
cylinder. Refer to Repair Procedure, How to
Remove the Secondary Boom Extension Cylinder.
How to R epair the Sec ondar y Boom C able Tr ac k
How to Repair the Secondary
Boom Cable Track
Note: If the section of cable track being replaced
has clamps or wear pads, those items will need to
be transferred to the replacement section of cable
track.
6
Remove the upper rollers from the
replacement section of cable track.
7
Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Note: A cable track repair kit is available through
the Genie Service Parts Department.
1
Remove the secondary boom extension
cylinder.
Note: The secondary boom extension cylinder must
be removed as an assembly with the cable tracks,
cable track trays and cable track support tubes from
the platform end of the secondary boom. Refer to
Repair Procedure, How to Remove the Secondary
Boom Extension Cylinder.
2
Visually inspect the cable track and determine
which 4-link section needs to be replaced.
Part No. 1268556
8
Connect the ends of the replacement cable
track section to the existing cable track using
the pins and snap rings.
9
Install the rollers onto the new section of cable
track.
10 Re-assemble and install the extension cylinder
assembly into the secondary extension boom.
11 Operate the secondary boom up/extend and
down/retract functions through a full cycle to
ensure smooth operation of the new section of
cable track.
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Service and Repair Manual
September 2016
Boom Components
4-7
Secondary Boom
How to Disassemble the
Secondary Boom
1
Remove the primary boom. Refer to Repair
Procedure, How to Remove the Primary
Boom.
2
Tag, disconnect and plug the hydraulic hoses
at the primary boom lift cylinder. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: Complete disassembly of the secondary
boom is only necessary if the outer or inner
secondary boom tube must be replaced. The
secondary extension boom tube can be removed
with the secondary boom tube on the machine.
Note: The extension cylinder can be removed
without completely disassembling the boom. Refer
to Repair Procedure, How to Remove the
Secondary Boom Extension Cylinder.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the machine on a
firm, level surface and in the stowed position with
the axles extended.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.
54
3
Attach a lifting strap from an overhead crane to
the lug on the barrel end of the primary boom
lift cylinder. Use the overhead crane to raise
the primary boom lift cylinder to a vertical
position.
4
Remove the pin retaining fastener from the
primary boom rod end pivot pin.
5
Use a slide hammer to remove the pin.
Remove the primary boom lift cylinder and
linkage arms from the machine.
Crushing hazard. The primary
boom lift cylinder and linkage
arms could become unbalanced
and fall if not properly supported
when the pin is removed.
6
At the platform end, remove the secondary
boom access cover.
7
Tag, disconnect and plug the hydraulic hoses
from the turntable. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
8
Tag and disconnect the electrical cables from
the turntable.
9
Remove the hose protector bracket.
10 Working at the platform end, place blocks
under the barrel end of the secondary boom
extension cylinder for support.
4-8
Secondary Boom Lift Cylinder
How to Remove the Secondary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
11 Remove the barrel-end retaining fasteners.
12 Using a suitable lifting device, lift the extension
cylinder to clear the saddle blocks
13 Attach a lifting strap from an overhead crane to
the secondary extension boom assembly.
14 Slide the secondary extension boom assembly
out of the secondary boom tube approximately
two feet and remove the wear pads from the
secondary boom tube.
15 Support and slide the extension boom
assembly out of the secondary boom tube and
place it on a structure capable of supporting it.
Crushing hazard. The extension
boom tube could become
unbalanced and fall if not
properly supported when
removed from the primary boom
tube.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the boom in the
stowed position.
1
Note: During removal, the overhead crane strap will
need to be adjusted for proper balancing.
16 To remove the secondary boom extension
cylinder, Refer to Repair Procedure, How to
Remove the Secondary Boom Extension
Cylinder.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
2
Part No. 1268556
Tag, disconnect, secure and remove the
battery cables connecting the batteries.
Remove battery fasteners and hooks from
battery tray. Remove the batteries and store
them in a safe and secure location away from
the machine.
Remove the retaining fasteners securing the
upper and lower turntable covers from the
turntable at the platform end. Remove the
covers.
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Service and Repair Manual
September 2016
Boom Components
3
Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out
away from the machine.
7
Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
Specifications, Machine Specifications.
Explosion and fire hazard.
Engine fuels are combustible.
Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
1 engine pivot plate anchor hole
2 engine pivot plate retaining fastener
4
5
Locate the engine pivot plate anchor hole at
the pivot end of the engine pivot plate.
Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
6
Remove the fuel tank filler cap.
Note: Be sure to only use a hand-operated pump
suitable for use with gasoline and diesel fuels.
8
Tag and disconnect the wire harness from the
fuel level sending unit.
9
Tag, disconnect and plug the fuel hoses from
the fuel tank.
10 Clean up any fuel that may have spilled.
11 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the
machine.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to
fall.
Note: Clean the fuel tank and inspect for cracks and
other damage before installing it onto the machine.
56
Part No. 1268556
September 2016
Service and Repair Manual
Boom Components
12 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift cylinder. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
13 Place blocks under each end of the secondary
boom lift cylinder for support.
4-9
Secondary Boom Extension
Cylinder
The secondary boom extension cylinder extends
and retracts the secondary boom extension tube.
The secondary boom extension cylinder is
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
How to Remove the Secondary
Boom Extension Cylinder
14 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
15 Use a soft metal drift to remove the pin.
16 Remove the pin retaining fastener from the
secondary boom lift cylinder barrel-end pivot
pin.
17 Use a soft metal drift to remove the pin.
18 Remove the secondary boom lift cylinder from
the machine by pulling it through the platform
end of the secondary boom.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly attached to the
overhead crane.
Component damage hazard.
When removing a secondary
boom lift cylinder from the
machine, be careful not to
damage the counterbalance
valve at the barrel end of the
cylinder.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: The secondary boom extension cylinder must
be removed as an assembly with the cable tracks,
cable track trays and cable track support tubes from
the platform end of the secondary boom.
1
Raise the primary boom to a horizontal
position.
2
Remove the access cover from the
counterweight end of the secondary boom.
Component damage hazard.
Cables and hoses can be
damaged if the cylinder is
dragged across them.
Part No. 1268556
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Service and Repair Manual
September 2016
Boom Components
3
Remove the fasteners securing the cable track
trays and cable track clamps to the secondary
extension boom.
4
Remove the external snap rings from the
extension cylinder rod-end pivot pin.
5
Use a soft metal drift to remove the pin.
6
Remove the access cover from the platform
end of the secondary boom.
7
Working at the platform end, place blocks
under the barrel end of the secondary boom
extension cylinder for support.
8
Remove the barrel-end retaining fasteners.
9
Using a suitable lifting device, lift the extension
cylinder to clear the saddle blocks.
10 Support and slide the extension cylinder out of
the boom extension and place it on a structure
capable of supporting it.
Crushing hazard. The
secondary boom extension
cylinder may become
unbalanced and fall if it is not
properly supported when it is
removed from the machine.
11 Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
12 Remove the cable track fasteners and cable
track support tubes from the extension
cylinder.
Component damage hazard. Be
careful not to damage the
secondary boom retract limit
switch when installing the
cylinder assembly into the
secondary boom. Secure the
roller arm to the switch body
during assembly.
Component damage hazard.
When removing the secondary
boom extension cylinder from the
machine, be careful not to
damage the counterbalance
valves at the barrel end of the
cylinder.
Component damage hazard.
Cables and hoses can be
damaged if the cylinder is
dragged across them.
58
Part No. 1268556
September 2016
Service and Repair Manual
Engines
5-1
RPM Adjustment
5-2
Flex Plate
Refer to Maintenance Procedure in the appropriate
Service or Maintenance Manual for your machine,
Check and Adjust the Engine RPM.
The flex plate acts as a coupler between the engine
and the pump. It is bolted to the engine flywheel
and has a splined center to drive the pump.
Type "B" flex plates combines the pump coupler, as
part of the flex plate, which is installed onto the
engine flywheel.
Type "B"
(flexplate with coupler combined)
How to R emove the Flex Pl ate
How to Remove the Flex Plate
Note: Perform this procedure with the engine off
and cool to the touch.
1
Open the engine side turntable cover.
2
Tag and disconnect the battery cables from the
battery(s).
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3
Part No. 1268556
Tag and disconnect the wiring plug at the
electronic displacement controller (EDC),
located on the drive pump.
59
Service and Repair Manual
September 2016
Engines
Deutz TD2011L04i models:
1
Tag and disconnect the wiring from the bell
housing.
2
Remove the U-bolt from the exhaust flex pipe
at the muffler.
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe burns.
3
Remove the muffler bracket retaining
fasteners from bell housing. Remove the
muffler and bracket assembly from the engine.
4
Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing engine fasteners.
5
Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
6
Remove the flex plate mounting fasteners, and
remove the flex plate from the engine flywheel.
3
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
4
Tag and disconnect the wiring from the bell
housing.
2
Support the drive pump with an appropriate
lifting device. Remove all of the bell housing
engine fasteners.
Remove the flex plate mounting fasteners, and
remove the flex plate from the engine flywheel.
Perkins 804D models:
1
Tag and disconnect the wiring from the bell
housing.
2
Remove the exhaust pipe clamp at the muffler.
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe burns.
3
Remove the muffler mounting bracket
fasteners. Remove the muffler and bracket
assembly from the engine.
4
Remove the hose clamps from the air cleaner
elbow and the engine intake manifold.
5
Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
assembly from the engine.
6
Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing to engine fasteners.
7
Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Deutz TD 2.9 models:
1
Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
8
60
Remove the flex plate mounting fasteners, and
remove the flex plate from the engine flywheel.
Part No. 1268556
September 2016
Service and Repair Manual
Engines
Perkins 404F-22T models:
Continental model:
1
Tag and disconnect the wiring from the bell
housing.
1
Tag and disconnect the wire harness from the
oxygen sensor.
2
Remove the fasteners supporting the muffler
assembly from the bell housing.
2
Remove the exhaust pipe heat shield
fasteners from the top of the muffler.
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe burns.
3
4
Support the drive pump with an appropriate
lifting device. Remove all of the bell housing to
engine fasteners.
Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
5
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe burns.
3
Remove the muffler retainer bracket fasteners.
4
Remove the muffler fasteners securing the
muffler to the exhaust manifold. Remove the
muffler from the bracket.
5
Remove the relay housing from the muffler
mount. Do not disconnect the relays.
6
Disconnect and remove the ECM from the
muffler mount.
7
Close the shutoff valve on the Liquid
Petroleum Gas (LPG) tank by turning it
clockwise (if equipped).
8
Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
9
Remove the muffler mount.
Remove the flex plate mounting fasteners, and
remove the flex plate from the engine flywheel.
10 Support the drive pump with an appropriate
lifting device. Remove all of pump plate
mounting fasteners.
11 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.
12 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine
flywheel.
Part No. 1268556
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Service and Repair Manual
September 2016
Engines
How to Ins tall the Fl ex Plate
How to Install the Flex Plate
1
Install the flex plate onto the engine flywheel
with the raised spline towards the pump. Apply
Loctite® removable thread sealant to the
mounting screws.
2
Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine.
3
Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
4
Install the pump onto the pump mounting plate.
Apply Loctite® removable thread sealant to the
pump retaining fasteners. Torque the pump
retaining fasteners to 57 ft-lbs / 77 Nm.
Note: Torque the flex plate mounting bolts in two
stages.
Continental models: Torque the flex plate
mounting bolts in sequence to 20.8 ft-lbs / 28
Nm.
Deutz models: Torque the flex plate mounting
bolts in sequence to 28 ft-lbs / 38 Nm. Then
torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm.
Perkins models: Torque the flex plate
mounting bolts in sequence to 28 ft-lbs / 38 Nm.
Then torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
5
Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine.
6
Install the pump and pump mounting plate
assembly onto the engine. Apply Loctite®
removable thread sealant to the mounting
screws.
Deutz, Perkins and Continental Flex Plate
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Part No. 1268556
September 2016
Service and Repair Manual
Engines
How to i nstall the Pump and Bell H ousing Ass embl y
How to Install the Pump and Bell
Housing Assembly
1
Deutz Pump Mounting Plate
Install the pump and bell housing assembly.
Deutz models: Torque the bell housing
mounting bolts labeled "C" in sequence to
28 ft-lbs / 38 Nm. Then torque the bell housing
mounting bolts labeled "C" in sequence to
40 ft-lbs / 54 Nm.
Perkins 804D models: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm and then to 49 ft-lbs / 66 Nm.
Perkins 404F models:Torque the bell
housing mounting bolts labeled "B" in
sequence to 28 ft-lbs / 38 Nm and the
mounting bolts labeled "A" to 49 ft-lbs / 66 Nm.
Then torque the bell housing mounting bolts
labeled "B" in sequence to 40 ft-lbs / 54 Nm
and the mounting bolts labeled "A" to 70 ft-lbs /
95 Nm.
Perkins 804D Pump Mounting Plate
Continental model:Torque the pump
mounting plate fasteners in sequence to
23 ft-lbs / 31.2 Nm.
Component damage hazard.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
Perkins 404F-22T Pump Mounting Plate
Continental Pump Mounting Plate
Part No. 1268556
63
Service and Repair Manual
September 2016
Engines
5-3
How to Access Perkins 404F
Engine Regeneration Service
Machines equipped with Perkins 404F-22T Diesel
engines will have a regeneration mode that should
run automatically when soot levels in the Diesel
Particulate Filter (DPF) reach specified levels.
How to Check the DPF Soot
Percentage
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus
Minus
Previous
Enter
1
Turn the key switch to the on position.
2
Press the plus button and the minus button at
the same time to access the Operator Status
menu.
3
Press the enter button twice to display DPF
SOOT PCT (0-150%).
How to Force or Inhibit DPF
Regeneration
There are three modes available for DPF
regeneration.
The default, AUTOMATIC MODE, allows for ECU
controlled regeneration. The machine powers up in
this mode.
INHIBIT DPF REGENERATION will disable
regeneration. In this mode the exhaust
temperatures will not raise due to regeneration. The
mode will remain active until an ignition key cycle
(power cycle) or FORCE DPF REGENERATION is
selected. This mode will be indicaed by an LCD
message while active.
FORCE DPF REGENERATION allow the operator
to force active regeneration of the DPF. When
Force mode is active the engine will enter
regeneration once the engine reaches specific
levels of DPF soot loading, exhaust temperature,
and other constraints defined by the engine
manufacturer. This mode will be indicated by an
LCD message while active.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus
64
Minus
Previous
Enter
1
Turn the key switch to the on position.
2
Press the plus button and the minus button at
the same time to access the Operator Status
menu.
Part No. 1268556
September 2016
Service and Repair Manual
Engines
3
Press the enter button until FORCE DPF
REGENERATION or INHIBIT DPF
REGENERATION is displayed.
4
Press the plus button or the minus button to
select YES to change the regeneration mode
from the default automatic mode. The
selection will automatically return to NO. The
LCD will display the current mode while it is
Inhibited or Forced.
Note: The LCD messages REGEN FORCED and
WARNING HIGH EXHAUST SYSTEM TEMP will
be displayed while a regeneration mode is running.
No service is required.
Note: The LCD message REGEN INHIBITED is
displayed while in the Inhibit Regeneration mode is
active. To exit this mode, push in the Red
emergency stop button. Restart the engine.
Part No. 1268556
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Service and Repair Manual
September 2016
Ground Controls
6-1
Bypass/Recovery Key Switch
The ground control box contains two key switches.
The main key switch towards the top of the control
box is for selection of ground or platform controls.
The key switch at the bottom of the control box is
the Bypass/Recovery key switch. Bypass and
Recovery modes are only intended for certain
circumstances and are not part of normal machine
operation. If either the Bypass or the Recovery
function is required, this indicates there may be
faults with the machine. Contact trained personnel
immediately.
Bypass is used for a platform out-of-envelope
condition and certain service situations.
Recovery is only to be used as a last attempt to
lower the platform when the operator in the platform
is unable to do so, system failure or in emergency
situations.
1 Run
2 Bypass
3 Recovery
66
Part No. 1268556
September 2016
Service and Repair Manual
Ground Controls
How to Use the Bypass Mode
Tip-over hazard. Operating the
machine outside of the operating
envelope while in Bypass mode
will result in death or serious injury
if proper operating procedures
and safety precautions are not
followed. Do not use this mode if
you are not trained and familiar
with the operating envelope of the
machine.
Note: Before using the Bypass mode, make sure
you understand the fault code or issue affecting the
operation of the machine to be sure the use of
bypass is required.
The Bypass mode will allow the platform to be
manually leveled when an out-of-level condition
exists. In the event that the platform angle is greater
than 10° from level, the boom angle and platform
level functions are disabled. Use of the Bypass
mode will allow the platform to be manually
adjusted to within the normal operating envelope,
±4.5°. Only auxiliary power can be used to correct
an out of level platform fault.
1
Turn the engine off.
2
Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.
3
Turn the bypass/recovery key switch to the
bypass position.
4
Using auxiliary power, operate the ground
control buttons to level the platform.
Note: Only the auxiliary power unit can be used to
correct an out of level platform fault.
5
Turn the bypass/recovery key switch to the run
position.
6
Remove the key from the bypass/recovery key
switch and insert the key into the main key
switch.
Note: If the Bypass function has been used, there
may be faults with the machine. Check the LCD
screen on the ground control box for machine faults,
then contact trained service personnel.
Note: The main key switch must remain in the
ground control position.
Part No. 1268556
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Service and Repair Manual
September 2016
Ground Controls
How to Us e the R ec overy Mode
How to Use the Recovery Mode
Recovery is only to be used as a last attempt to
lower the platform when the operator in the platform
is unable to do so, system failure or in emergency
situations.
Bodily injury hazard. When using
recovery mode, the platform may
not fully lower to the ground when
the recovery mode is completed.
Failure to use only suitable
equipment and/or practices to
allow the operator to safely exit
the platform could result in death
or serious injury.
Bodily injury hazard. Platform
leveling is not active when using
recovery mode. The platform
could reach high out-of-level
conditions when using this mode.
The operator will need to secure
themself to the platform to
prevent falling injury.
The Recovery mode allows the platform to be
lowered in the event the operator in the platform is
unable to lower the platform using the platform
controls, system failure or emergency situations.
The recovery sequence will automatically retract
the primary boom, lower the primary boom and then
retract the secondary boom using the auxiliary
power unit to allow the operator at the platform
controls to exit the platform.
68
1
Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.
Note: If this procedure is performed with the main
key switch in the off position an active latched
safety fault will be set and will have to be cleared.
2
Turn and hold the bypass/recovery key switch
to the recovery position. The switch must be
held in the recovery position.
Result: The auxiliary power unit will turn on
and the boom will begin the following recovery
sequence.
• The primary boom will retract.
• The primary boom will lower.
• The secondary boom will retract.
Note: The key switch must be held in the recovery
position until the recovery sequence is complete or
until the operator in the platform can safely exit the
platform.
Note: If any boom safety limit switches are faulty,
the boom will only retract and not lower and the
operator will need to be recovered from that point.
Note: If the Recovery function has been used, this
may indicate there may be faults with the machine.
Tag and remove the machine from service until the
fault has been corrected by trained personnel.
Part No. 1268556
September 2016
Service and Repair Manual
Ground Controls
6-2
Circuit Boards
How to Determine the Revision
Level
The ground control box (TCON) is the
communication and operations center for the
machine. The ground control box contains two key
switches. The key switch towards the top of the
control box is for selection of ground or platform
controls. The key switch at the bottom of the control
box is the Service Bypass key switch. It is used to
correct an out-of-level platform. If the machine trips
an envelope safety switch, the operator at the
ground controls can turn and hold the Service
Bypass key switch in the recover position, which will
automatically retract the boom and lower the
platform to the ground.
1
1
Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
The ground control box contains a replaceable
membrane decal with touch sensitive buttons for
various machine functions. The ground control box
also contains two printed circuit boards:
2
Remove the ground control box lid fasteners.
3
Open the ground control box.
Result: The revision level of the TCON will
appear in the LCD display window.
How to Remove the LCD Display
Screen Circuit Board
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
The LCD (Liquid Crystal Display) circuit board is
mounted to the inside of the control box lid which
controls the LCD display screen or CAN Gateway if
equipped with a Tier IV engine.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
The TCON circuit board is the main circuit board
for the machine. There are relays on the ECM
circuit board that can be replaced. All operating
parameters and configuration of options for the
machine are stored in the ECM memory.
Note: The ECM circuit board inside the ground
control box (TCON) cannot be replaced by itself. If
the ECM circuit board is faulty and needs to be
replaced, contact the Genie Industries Service
Department.
Note: When an ECM circuit board is replaced, the
proportional valves will need to be calibrated. Refer
to Repair Procedure, How to Calibrate a Joystick.
Part No. 1268556
Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
position at both platform and ground controls.
4
Carefully disconnect the LCD circuit board
ribbon cable from the ECM circuit board.
5
Remove the LCD display circuit board
retaining fasteners.
6
Carefully remove the LCD display circuit board
from the ground control box lid.
69
Service and Repair Manual
September 2016
Ground Controls
6-3
Membrane Decal
4
The membrane decal is a special decal that
consists of a decal with an electronic membrane on
the backside. The membrane contains touch
sensitive areas that, when pushed, activate the
machine functions. The membrane contains touch
sensitive areas that activate the machine functions.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
How to Replace the Membrane
Decal
1
Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
2
Remove the ground control box lid fasteners.
3
Open the ground control box.
Carefully disconnect the two ribbon cables
from the membrane decal at the ECM circuit
board.
5
Carefully remove the membrane decal from
the control box lid while guiding the ribbon
cables out of the control box lid.
6
Remove any decal adhesive from the control
box lid with a mild solvent.
Note: Do not allow any solvent to come in contact
with the LCD display screen.
70
7
Install the new membrane decal while guiding
the ribbon cables through the control box lid.
8
Connect the ribbon cables to the ECM circuit
board.
9
Close the control box lid and install the
retaining fasteners.
Part No. 1268556
September 2016
Service and Repair Manual
Display Module
This table lists the various screens and menu options of the operating software. Some display menus are for
informational purpose only, while others can be used to change the machine operating parameters.
Tip-over hazard. Calibration and parameter settings must be completed by a person
trained and qualified on the repair of this machine. Failure to properly calibrate or set
parameters could cause the machine to tip over resulting in death or serious injury.
Note: The key switch must be in the off position before entering the programming mode.
Note: Use the following chart to identify the description of each LCD screen control button used in this
procedure.
Plus
Minus
Previous
Enter
Activation of the enter or previous buttons scrolls through the screens. To change parameter values or
select a setting, use the plus button (to increase or scroll forward) and the minus button (to decrease or
scroll backwards). Then press the enter button to save the new value to memory. An audible beep will
indicate a save to memory. Use the enter and previous buttons to scroll to the EXIT menu. Use the plus
button to change to YES and use the enter button to exit.
Screen or Menu
Operator
Procedure
Default
Description
Range or Selection
Hourmeter (on power up)
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature °F (Engiish)
engine temp will not display
until temp is >100°F
Engine temperature °C (metric)
engine temp will not display
until temp is >38°C
Primary boom angle to gravity
Turntable level sensor X° direction
Turntable level sensor Y° direction
Platform level sensor degree
Battery volts
Part No. 1268556
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Service and Repair Manual
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Display Module
Screen or Menu
Procedure
Machine Status With key switch on, press the
(plus)(minus) buttons at the same
time.
Description
Hydraulic pressure PSI
(English)
0-4500 PSI
Hydraulic pressure kPa (metric) 0-31000 kPa
DPF Soot
0-150%
Force/Inhibit DPF
Regeneration
(No/Yes)
Primary Boom Zone
<=0 DEG, >0 DEG, =65
DEG
Primary Boom Length
= 0’, >0’, >22’
Secondary Boom Length
= 0 FT, > 0 FT
Secondary Boom Angle
= 0 DEG, .>0 DEG, = 65
DEG
Unit of Measure With key switch OFF, press and hold
Metric/English (measurement
and Language the enter button and turn key switch to units)
on position.
Display Language
Release the enter button and press
(plus)(minus)(minus)(plus).
Default Reset
Range or Selection
Use plus/minus buttons
to change
English, German,
French, Spanish,
Portuguese, Italian,
Dutch, and Swedish.
Delete drive functions
With key switch OFF, press and hold
the enter button and turn key switch to
Delete boom function speed
on position.
Release the enter button and press
Delete lift function ramps
(minus)(minus)(previous)(previous)
Delete all (Contact Genie
Product Support before using
this option)
Delete Faults
72
Delete faults will reset
active latching faults.
Delete faults will not
clear fault history.
Part No. 1268556
September 2016
Service and Repair Manual
Display Module
Screen or Menu
Drive Functions
Part No. 1268556
Procedure
Description
Range or Selection
With key switch OFF, press
and hold the enter button
and turn key switch to on
position.
Release the enter button
and press
(plus)(plus)(enter)(enter).
Forward not stowed drive speed % 120% (default) 50% (min)
Forward low drive speed %
120% (default) 50% (min)
Forward high drive speed %
120% (max) 100% (default)
50% (min)
Reverse not stowed drive
speed %
120% (max) 100% (default)
50% (min)
Forward extended drive
speed %
Reverse low drive speed %
120% (max) 100% (default)
50% (min)
Reverse extended drive
speed %
Reverse high drive speed %
120% (max) 100% (default)
50% (min)
Drive acceleration %
125% (max) 100% (default)
25% (min)
Drive deceleration %
125% (max) 100% (default)
25% (min)
Speed limit on steer angle
100% (max) 75% (default)
0% (min)
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Service and Repair Manual
September 2016
Display Module
Screen or Menu
Boom Function
Speeds
Procedure
Description
Range or Selection
Primary boom up speed stowed
120% max, 50% min,
With key switch OFF, press
and hold the enter button
100% (default)
and turn key switch to on
Primary boom up speed not stowed
position.
Release the enter button
Primary boom down speed stowed
and press
(plus)(plus)(minus)(minus)
Primary boom down speed not
stowed
Primary boom extend speed
Primary boom retract speed
Secondary boom up speed stowed
Secondary boom up speed not
stowed
Secondary boom down speed
stowed
Secondary boom down speed not
stowed
Secondary boom extend speed
Secondary boom retract speed
Turntable rotate speed retracted
Turntable rotate speed not retracted
Jib boom up speed
120% max, 75% min,
100% (default)
Jib boom down speed
74
Part No. 1268556
September 2016
Service and Repair Manual
Display Module
Screen or Menu
Procedure
Lift Functions
Ramps
With key switch OFF, press and
hold the enter button and turn key
switch to on position.
Release the enter button and
press
(plus)(plus)(previous)(previous).
Description
Range or Selection
Primary boom up/down ramp
acceleration %
150% max and 50% min
100% (default),
Primary boom up/down ramp
deceleration %
5% increment
Primary boom extend/retract
ramp acceleration %
Primary boom extend/retract
ramp deceleration %
Secondary boom up/down ramp
acceleration %
Secondary boom up/down ramp
deceleration %
Turntable rotate ramp
acceleration %
Turntable rotate ramp
deceleration %
Jib boom up/down ramp
acceleration %
Jib boom up/down ramp
deceleration %
Part No. 1268556
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Service and Repair Manual
September 2016
Display Module
Screen or Menu
Valve Calibration
Procedure
With key switch OFF, press and
hold the enter button and turn
key switch to on position.
Release the enter button and
press
(minus)(minus)(enter)(enter).
Description
Reset drive valve defaults
Range or Selection
YES/NO
Reset primary boom up/down
valve defaults
Reset primary boom ext/ret
defaults
Reset secondary boom valve
defaults
Reset turntable rotate valve
defaults
Allow primary boom up/down
speed calibration
Allow primary boom
extend/retract speed
calibration
Allow secondary boom
up/down speed calibration
Allow turntable rotate speed
calibration
Reset Drive joystick defaults
Reset primary boom up/down
joystick defaults
Reset primary boom
extend/retract joystick defaults
Reset secondary boom
joystick defaults
Reset turntable rotate joystick
defaults
Reset steer joystick defaults
76
Part No. 1268556
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Service and Repair Manual
Display Module
Screen or Menu
Sensor Calibration
Procedure
With key switch OFF, press
and hold the enter button
and turn key switch to on
position.
Release the enter button
and press
(plus)(enter)(enter)(plus).
Description
Set unit levels to gravity
Range or Selection
YES/NO
Unit Level Y-axis millivolts per
degree
Unit Level X-axis millivolts per
degree
Set platform level to gravity
Platform level sensor
millivolts/degree
Reset blue end blue side steer
sensor
Reset yellow end blue side steer
sensor
Reset blue end yellow side steer
sensor
Reset yellow end yellow side steer
sensor
Reset all steer sensors
Reset primary boom angle sensor
Primary boom angle = 40deg
Primary boom angle = 70deg
Part No. 1268556
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Service and Repair Manual
September 2016
Display Module
Screen or Menu
Options
Procedure
With key switch OFF, press
and hold the enter button
and turn key switch to on
position.
Release the enter button and
press
(minus)(minus)(plus)(plus).
Description
Range or Selection
Boom Length Limit: No Limit (NO
LT),
Secondary Extend disabled (EXT
LT),
Secondary Function disabled (SEC
LT)
AC Generator
(NONE/BELT/HILO/HYDRL/GHG10)
Alarm No (NO AL)/Motion (MO AL)
Travel (TR AL)/ Descent (DE AL)/
Travel and Descent (TD AL)
Lift/Drive No (NO CO)/ Drive cut out
while not stowed (DCONS)/ Lifting or
driving (LORDR)
Aux Drive OPT: (YES/NO)
Proximity Kill Switch (NONE/PROX)
Platform Overload (NONE PLFTS)
Work Lights (YES/NO)
Flashing Beacon (YES/NO)
Drive Lights (YES/NO)
Disable Steer Mode Change while
Driving (YES/NO)
Rocker Joystick Steering (YES/NO)
Chassis Tilt Cutout (YES/NO)
Foot Switch Lockout (0-30 minutes)
30.0 max and 0.0 min,
10.0 (default)
Holding +/- button will
cause display to scroll
through options or
increment number
settings automatically at
0.2 min
increase/decrease
78
Part No. 1268556
September 2016
Service and Repair Manual
Hydraulic Pumps
7-1
Function Pump
2
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Function
Pump
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
Models without hydraulic tank shutoff
valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Specifications, Machine Specifications.
Tag, disconnect and plug the hydraulic hoses
at the function pump. Cap the fittings on the
pump.
3
Remove the function pump mounting bolts.
Carefully remove the pump.
Component damage hazard. Be
sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
open
closed
Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
Part No. 1268556
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Service and Repair Manual
September 2016
Hydraulic Pumps
7-2
Drive Pump
2
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should be performed at an authorized
Sauer-Danfoss service center. Contact Genie
Product Support to locate your local authorized
service center.
Models without hydraulic tank shutoff
valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Specifications, Machine Specifications.
Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where
this procedure will be performed
must be clean and free of debris
that could get into the hydraulic
system and cause severe
component damage. Dealer
service is recommended.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
80
open
closed
Disconnect the electrical connectors at the
electrical proportional controller located on the
drive pump.
Part No. 1268556
September 2016
Service and Repair Manual
Hydraulic Pumps
How to Prime the Pump
3
Tag and disconnect and plug the hydraulic
hoses from the drive and function pumps. Cap
the fittings on the pumps.
How to Prime the Pump
Component damage hazard. Be
sure that the hydraulic tank
shutoff valves (if equipped) are in
the open position before priming
the pump. The engine must not
be started with the hydraulic tank
shutoff valves in the closed
position or component damage
will occur.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4
Support the pump with a lifting device and
remove the pump mounting fasteners.
5
Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
6
Remove the drive pump from the machine.
1
Connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2
Continental models: If equipped, close the
valve on the LPG tank, then disconnect the
hose from the tank. Move the fuel select toggle
switch to the LPG position.
Component damage hazard. Be
sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Deutz and Perkins models: Disconnect the
engine wiring harness from the fuel solenoid at
the injector pump.
3
Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
pressure reaches 300 psi / 20.7 bar.
4
Continental models: If equipped, connect the
LPG hose to the LPG tank and open the valve
on the tank.
Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
5
Part No. 1268556
Start the engine from the ground controls and
check for hydraulic leaks.
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Service and Repair Manual
September 2016
Manifolds
8-1
Function Manifold Components - View 1
The function manifold is mounted to the turntable next to the ground controls.
Index
Description
No.
Schematic
Function
Item
Torque
1
Differential sensing valve
A
Secondary boom up/extend and
down/retract
30-35 ft-lbs / 41-47 Nm
2
Relief valve, 2500 psi / 172 bar
B
Secondary boom up
20-25 ft-lbs / 27-34 Nm
3
Solenoid valve, 2 position 2 way
C
Secondary boom up circuit
20-25 ft-lbs / 27-34 Nm
4
Relief valve, 2500 psi / 172 bar
D
Secondary boom down
20-25 ft-lbs / 27-34 Nm
5
Relief valve, 1300 psi / 89.6 bar
E
Primary boom down
20-25 ft-lbs / 27-34 Nm
6
Flow regulator valve, 0.1 gpm / 0.38
L/min
F
Bleeds off check valves
indifferential sensing circuits to
tank
20-25 ft-lbs / 27-34 Nm
7
Proportional solenoid valve
G
Primary boom up/down
30-35 ft-lbs / 41-47 Nm
8
Solenoid valve, 2 position 3 way
H
Primary boom retract
33-37 ft-lbs / 45-50 Nm
9
Check valve
I
Differential sensing
circuit,primary boom
extend/retract
8-10 ft-lbs / 11-14 Nm
10
Solenoid valve, 2 position 3 way
J
Primary boom extend
50-55 ft-lbs / 68-75 Nm
11
Differential sensing valve
K
Turntable rotate left/right
30-35 ft-lbs / 41-47 Nm
12
Differential sensing valve
L
Primary boom extend/retract
30-35 ft-lbs / 41-47 Nm
13
Differential sensing valve
M
Primary boom up/down
30-35 ft-lbs / 41-47 Nm
14
Priority flow regulator valve, 3 gpm /
11.4 L/min
N
Controls flow to the oscillateand
platform manifolds
30-35 ft-lbs / 41-47 Nm
15
Solenoid valve, 3 position 4 way
O
Secondary boom extend/retract
33-37 ft-lbs / 45-50 Nm
82
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Service and Repair Manual
Manifolds
Part No. 1268556
83
Service and Repair Manual
September 2016
Manifolds
8-1
Function Manifold Components - View 1
The function manifold is mounted to the turntable next to the ground controls.
Index
Description
No.
Schematic
Function
Item
Torque
1
Solenoid valve, 2 position 2 way
P
Secondary boom extend circuit
20-25 ft-lbs / 27-34 Nm
2
Relief valve, 2600 psi / 179 bar
Q
Secondary boom extend
20-25 ft-lbs / 27-34 Nm
3
Proportional solenoid valve
R
Turntable rotate left/right
20-25 ft-lbs / 27-34 Nm
4
Solenoid valve, 3 position 4 way
S
Turntable rotate left/right
26-30 ft-lbs / 35-41 Nm
5
Check valve
T
Differential sensing
circuit,turntable rotate
8-10 ft-lbs / 11-14 Nm
6
Relief valve, 1300 psi / 89.6 bar
U
Primary boom extend
30-35 ft-lbs / 41-47 Nm
7
Solenoid valve, 2 position 3 way
V
Primary boom up
33-37 ft-lbs / 45-50 Nm
8
Proportional solenoid valve
W
Primary boom extend/retract
30-35 ft-lbs / 41-47 Nm
9
Solenoid valve, 2 position 3 way
X
Primary boom down
33-37 ft-lbs / 45-50 Nm
10
Check valve
Y
Differential sensing
circuit,primary boom up/down
11
Solenoid valve, 2 position 3 way
Z
Secondary boom up
33-37 ft-lbs / 45-50 Nm
12
Solenoid valve, 2 position 3 way
AA
Secondary boom down
33-37 ft-lbs / 45-50 Nm
13
Proportional solenoid valve
AB
Secondary boom extend/retract
30-35 ft-lbs / 41-47 Nm
14
Check valve
AC
Differential sensing
circuit,secondary boom
extend/retract
15
Check valve, 5 psi / 0.34 bar
AD
Blocks flow from auxiliarypump
#1 to function pump #1
30-35 ft-lbs / 41-47 Nm
16
Check valve, 5 psi / 0.34 bar
AE
Blocks flow from function pump
#1to auxiliary pump #1
20-25 ft-lbs / 27-34 Nm
17
Check valve, 5 psi / 0.34 bar
AF
Blocks flow from auxiliarypump
#2 to function pump #2
20-25 ft-lbs / 27-34 Nm
18
Relief valve, 3000 psi / 207 bar
AG
Oscillate and platform
manifoldsystem relief
20-25 ft-lbs / 27-34 Nm
19
Check valve, 5 psi / 0.34 bar
AH
Blocks flow from function pump
#2to auxiliary pump #2
20-25 ft-lbs / 27-34 Nm
20
Differential sensing valve,150 psi /
10.3 bar
AI
Meters flow to functions
30-35 ft-lbs / 41-47 Nm
21
Relief valve, 3200 psi / 220.6 bar
AJ
Boom functions system relief
30-35 ft-lbs / 41-47 Nm
84
8-10 ft-lbs / 11-14 Nm
8-10 ft-lbs / 11-14 Nm
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Manifolds
Part No. 1268556
85
Service and Repair Manual
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Manifolds
8-3 Valve Adjustments - Function
Manifold
6
How to Adjust the System Relief
Valve
Simultaneously push and hold the function
enable/high speed button and the primary
boom retract button with the primary boom fully
retracted. Observe the reading on the pressure
gauge. Refer to Specifications, Hydraulic
Specifications.
7
Note: Perform this procedure with the boom in the
stowed position.
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
8
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
How to Adj ust the System Reli ef Val ve
Note: Refer to Function Manifold Component list to
locate the system relief valve.
1
Locate the boom retracted limit switch
(LSP1RO) limit switch on the outside of the
primary boom at the pivot end of the primary
boom.
2
Tag and disconnect the wire harness from the
limit switch, and install a wire jumper between
pins 1 and 2 of the limit switch connector.
Place another wire jumper between pins 3 and
4 of the limit switch connector.
10 Remove the pressure gauge.
3
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ptest port on the
function manifold.
12 Securely install the LSP1RO pig tail into the
wire harness.
4
Start the engine from the ground controls.
5
Press and release the rpm select button until
the engine changes to high idle.
86
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9
Repeat steps 4 through 8 confirm the relief
valve pressure.
11 Remove the wire jumpers from the limit switch
connector.
Part No. 1268556
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Service and Repair Manual
Manifolds
How to Adj ust the Pri mar y Boom Down R elief Val ve
How to Adjust the Primary Boom
Down Relief Valve
8
Note: Perform this procedure with the boom in the
stowed position.
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
Note: Refer to Function Manifold Component list to
locate the primary boom down relief valve.
1
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ls port on the function
manifold.
2
Start the engine from the ground controls.
3
Press and release the rpm select button until
the engine changes to high idle.
10 Start the engine and raise the primary boom
approximately 12 inches / 30 cm. Remove the
block and lower the primary boom to the
stowed position.
4
Raise the primary boom approximately 5 feet /
1.5 m.
11 Turn the engine off and remove the pressure
gauge.
5
Place a 4 x 4 inch / 10 x 10 cm block on the
primary boom rest pad. Lower the primary
boom onto the block.
9
Start the engine and repeat steps 6 through
8 to confirm the relief valve pressure.
Crushing hazard. Keep hands
clear of the block when lowering
the primary boom.
6
Simultaneously push and hold the function
enable/high speed button and the primary
boom down button. Observe the pressure
reading on the pressure gauge. Refer to
Specifications, Hydraulic Specifications.
7
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
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Manifolds
How to Adj ust the Pri mar y Boom Extend R elief Val ve
How to Adjust the Primary Boom
Extend Relief Valve
Note: Refer to Function Manifold Component list to
locate the primary boom extend relief valve.
1
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ls port on the function
manifold.
9
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
10 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
2
Start the engine from the ground controls.
3
Raise the boom to a horizontal position. Turn
the engine off.
11 Repeat steps 7 through 8 to confirm relief
valve pressure.
4
Locate the boom extended limit switch
(LSP1EO) on the outside of the primary boom.
12 Start the engine and fully retract the primary
boom. Turn the engine off.
5
Remove the limit switch mounting bracket
retaining fasteners.
13 Install the limit switch and bracket assembly to
the primary boom.
6
Pull the limit switch and bracket assembly out
of the boom tube and let it hang down.
14 Remove the pressure gauge.
7
Start the engine from the ground controls and
press and release the rpm select button until
the engine changes to high idle.
8
Simultaneously push and hold the function
enable/high speed button and the primary
boom extend button with the primary boom
fully extended. Observe the reading on the
pressure gauge. Refer to Specifications,
Hydraulic Specifications.
88
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Manifolds
How to Adj ust the Sec ondary Boom U p Reli ef Val ve
How to Adjust the Secondary
Boom Up Relief Valve
7
Continue holding the function enable/high
speed button and the secondary boom
up/extend button while observing the reading
on the pressure gauge. Refer to
Specifications, Hydraulic Specifications.
8
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
9
Note: Refer to Function Manifold Component list to
locate the secondary boom up relief valve.
1
Remove the cover retaining fasteners from the
secondary boom end cover. Remove the cover
from the machine.
2
Locate the wire connector for secondary boom
limit switch LSS2AO. Disconnect the
connector.
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Note: The secondary boom limit switch LSS2AO is
the upper limit switch located on the inside of the
riser plate at the engine side of the machine.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
3
Install a jumper wire between pins 3 and 4 of
the LSS2AO Deutsch connector on the wire
harness end.
4
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ls port on the function
manifold.
5
Start the engine from the ground controls.
6
Simultaneously push and hold the function
enable/high speed button and the secondary
boom up/extend button and fully raise the
secondary boom.
Part No. 1268556
10 Repeat steps 5 through 7 to confirm relief
valve pressure.
11 Remove the pressure gauge.
12 Remove the jumper wire from LSS2AO limit
switch connector. Connect the limit switch to
the wire harness.
13 Install the secondary boom end cover and
tighten the retaining fasteners.
89
Service and Repair Manual
September 2016
Manifolds
How to Adj ust the Sec ondary Boom D own Relief Val ve
How to Adjust the Secondary
Boom Down Relief Valve
8
Note: Refer to Function Manifold Component list to
locate the secondary boom down relief valve.
1
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ls port on the function
manifold.
2
Start the engine from the ground controls.
3
Press and release the rpm select button until
the engine changes to high idle.
4
Raise the secondary boom approximately
12 inches / 30 cm.
5
Place a 4 x 4 inch / 10 x 10 cm block on the
secondary boom rest pad. Lower the
secondary boom onto the block.
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9
Start the engine and repeat step to confirm
relief valve pressure.
10 Start the engine and raise the secondary boom
approximately 12 inches / 30 cm. Remove the
block and lower the secondary boom to the
stowed position.
11 Turn the engine off and remove the pressure
gauge.
Crushing hazard. Keep hands
clear of the block when lowering
the primary boom.
6
Simultaneously push and hold the function
enable/high speed button and the secondary
boom down button. Observe the reading on
the pressure gauge. Refer to Specifications,
Hydraulic Specifications.
7
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
90
Part No. 1268556
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Service and Repair Manual
Manifolds
How to Adj ust the Sec ondary Boom Extend R elief Val ve
How to Adj ust the Pl atfor m M anifold Reli ef Val ve
How to Adjust the Secondary
Boom Extend Relief Valve
How to Adjust the Platform
Manifold Relief Valve
Note: Perform this procedure with the secondary
boom fully raised.
Note: Perform this procedure with the boom in the
stowed position.
Note: Refer to Function Manifold Component list to
locate the secondary boom extend relief valve.
Note: Refer to Function Manifold Component list to
locate the platform manifold relief valve.
1
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ls port on the function
manifold.
1
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ptest 2 port on the
function manifold.
2
Start the engine from the ground controls.
2
Start the engine from the ground controls.
3
Simultaneously push and hold the function
enable/high speed button and the secondary
boom up/extend button with the secondary
boom fully raised and extended. Observe the
pressure reading on the pressure gauge. Refer
to Specifications, Hydraulic Specifications.
3
Simultaneously push and hold the function
enable/high speed button and the jib boom
down button with the jib boom fully lowered.
Observe the reading on the pressure gauge.
Refer to Specifications, Hydraulic
Specifications.
4
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
4
Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
5
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap
5
Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6
Repeat steps 2 through 5 to confirm relief
valve pressure.
6
Repeat steps 2 through 3 to confirm relief
valve pressure.
7
Remove the pressure gauge.
7
Remove the pressure gauge.
Part No. 1268556
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Service and Repair Manual
September 2016
Manifolds
8-4
Platform Manifold
The platform Manifold is mounted to the platform mounting weldment.
Index
Description
No.
1
Check valve, 5 psi
2
3
Schematic
Function
Item
Torque
HA
Platform load sense/level circuit
12-14 ft-lbs / 16-19 Nm
Differential sensing valve, N.C.
HB
Directs flow to functions
19-21 ft-lbs / 26-29 Nm
Check valve, 5 psi
HC
Jib load sense/up/down circuit
12-14 ft-lbs / 16-19 Nm
4
Flow control valve
HD
Bleeds off differential valve to
tank
19-21 ft-lbs / 26-29 Nm
5
Accumulator, 500 psi / 34.5 bar
HE
Hydraulic dampening
6
Proportional solenoid
valve,2 position 2 way
HF
7
Proportional solenoid
valve3 position 5 way
HG
8
Check valve, 10 psi
HH
9
Compensator valve
HI
Jib boom differential sensing
circuit
33-37 ft-lbs / 45-50 Nm
10
Compensator valve
HJ
Platform level diff. sensing circuit
33-37 ft-lbs / 45-50 Nm
11
Pressure compensation valve
HK
Platform rotate diff. sensing
circuit
19-21 ft-lbs / 26-29 Nm
12
Proportional solenoid
valve3 position 5 way
HL
Platform level up/down circuit
19-21 ft-lbs / 26-29 Nm
13
Proportional solenoid
valve3 position 5 way
HM
Platform rotate left/right circuit
19-21 ft-lbs / 26-29 Nm
92
23 ft-lbs / 31 Nm
19-21 ft-lbs / 26-29 Nm
Jib up/down circuit
19-21 ft-lbs / 26-29 Nm
19-21 ft-lbs / 26-29 Nm
Part No. 1268556
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Manifolds
Part No. 1268556
93
Service and Repair Manual
September 2016
Manifolds
8-5
Turntable Rotation Manifold
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index
Description
No.
Schematic
Function
Item
Torque
1
Shuttle valve, 2 position 3 way
KK
Turntable rotation brake release
10-13 ft-lbs / 14-18 Nm
2
Counterbalance valve
LL
Turntable rotate right
35-40 ft-lbs / 47-54 Nm
3
Counterbalance valve
MM
Turntable rotate left
35-40 ft-lbs / 47-54 Nm
94
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Manifolds
8-6
Platform Rotate Manifold
The platform rotate manifold is mounted on the platform rotator.
Index
Description
No.
Schematic
Function
Item
Torque
1
Counterbalance valve
HA
Turntable rotation brake release
35-40 ft-lbs / 47-54 Nm
2
Counterbalance valve
HB
Turntable rotate left
35-40 ft-lbs / 47-54 Nm
Part No. 1268556
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Service and Repair Manual
September 2016
Manifolds
8-7
Two Wheel Steer and Oscillate Manifold
The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index
Description
No.
Schematic
Function
Item
Torque
1
Solenoid valve, 3 position 4 way
JA
Steer left/right, yellow side steer
cylinder
26-30 ft-lbs / 35-41 Nm
2
Solenoid valve, 3 position 4 way
JB
Steer left/right, blue side steer
cylinder
26-30 ft-lbs / 35-41 Nm
3
Solenoid valve, 2 position 3 way
JC
Oscillate cylinder, blue side
26-30 ft-lbs / 35-41 Nm
4
Solenoid valve, 2 position 3 way
JD
Oscillate cylinder, yellow side
26-30 ft-lbs / 35-41 Nm
5
Relief valve, 750 to 860 psi /
51.71 to 59.3 bar
JE
Oscillate circuit
20-25 ft-lbs / 27-34 Nm
6
Flow regulator valve, 1.5 gpm / 5.7
L/min
JF
Blue side steer cylinder extend
circuit
20-25 ft-lbs / 27-34 Nm
7
Flow regulator valve, 1.0 gpm / 3.8
L/min
JG
Blue side steer cylinder retract
circuit
20-25 ft-lbs / 27-34 Nm
8
Check valve
JH
Load sensing circuit,blue side
steer cylinder retract
8-10 ft-lbs / 11-14 Nm
9
Check valve
JI
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
10
Check valve
JJ
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
11
Flow regulator valve, 1.5 gpm / 5.7
L/min
JK
Yellow side steer cylinderextend
circuit
20-25 ft-lbs / 27-34 Nm
12
Flow regulator valve, 1.0 gpm / 3.8
L/min
JL
Yellow side steer cylinderretract
circuit
20-25 ft-lbs / 27-34 Nm
13
Check valve, 65 psi / 4.5 bar
JM
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
14
Check valve, 65 psi / 4.5 bar
JN
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
15
Check valve
JO
Load sensing circuit,yellow side
steer cylinder retract
8-10 ft-lbs / 11-14 Nm
16
Check valve
JP
Load sensing circuit,yellow side
steer cylinder extend
8-10 ft-lbs / 11-14 Nm
17
Check valve
JQ
Load sensing circuit,blue side
steer cylinder extend
8-10 ft-lbs / 11-14 Nm
96
Part No. 1268556
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Part No. 1268556
97
Service and Repair Manual
September 2016
Manifolds
How to Adj ust the Oscill ate R elief Val ve
How to Adjust the Oscillate Relief
Valve
Note: Perform this procedure with the boom in the
stowed position.
Note: This procedure will require two people.
Note: Refer to Oscillate Manifold Component list to
locate the oscillate relief valve.
1
Remove the drive chassis cover from the
square-end of the machine.
2
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the two
wheel steer and oscillate manifold.
3
Start the engine from the platform controls.
4
Press down the foot switch and manually
activate one of the oscillate limit switches. Hold
the switch in the activated position and
observe the reading on the pressure gauge.
Refer to Specifications, Hydraulic Component
Specifications.
5
Turn the engine off. Use a wrench to hold the
relief valve and loosen the jam nut.
6
Adjust the stud with a hex wrench. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Tighten the jam nut.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7
Repeat steps 3 through 4 to confirm relief
valve pressure.
8
Remove the pressure gauge.
9
Install the drive chassis cover.
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Part No. 1268556
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Service and Repair Manual
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Manifolds
8-8
Four Wheel Steer and Oscillate Manifold
The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index
Description
No.
Schematic
Function
Item
Torque
1
Solenoid valve, 3 position 4 way
KA
Steer left/right, square endyellow
side steer cylinder
26-30 ft-lbs / 35-41 Nm
2
Solenoid valve, 3 position 4 way
KB
Steer left/right, square endblue
side steer cylinder
26-30 ft-lbs / 35-41 Nm
3
Check valve
KC
Load sensing circuit, circle
endyellow side steer cylinder
retract
8-10 ft-lbs / 11-14 Nm
4
Check valve, 65 psi / 4.5 bar
KD
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
5
Solenoid valve, 2 position 3 way
KE
Oscillate cylinder, blue side
26-30 ft-lbs / 35-41 Nm
6
Solenoid valve, 2 position 3 way
KF
Oscillate cylinder, yellow side
26-30 ft-lbs / 35-41 Nm
7
Check valve, 65 psi / 4.5 bar
KG
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
8
Relief valve, 750 to 860 psi /
51.71 to 59.3 bar
KH
Oscillate circuit
20-25 ft-lbs / 27-34 Nm
9
Flow regulator valve, 1.5 gpm / 5.7
L/min
KI
Circle end, blue side steer
cylinder extend circuit
20-25 ft-lbs / 27-34 Nm
10
Flow regulator valve, 1.0 gpm / 3.8
L/min
KJ
Circle end, blue side steer
cylinderretract circuit
20-25 ft-lbs / 27-34 Nm
11
Flow regulator valve, 1.0 gpm / 3.8
L/min
KK
Circle end, yellow side steer
cylinderretract circuit
20-25 ft-lbs / 27-34 Nm
12
Flow regulator valve, 1.5 gpm / 5.7
L/min
KL
Circle end, yellow side steer
cylinderextend circuit
20-25 ft-lbs / 27-34 Nm
13
Check valve
KM
Load sensing circuit, circle
endblue side steer cylinder
retract
8-10 ft-lbs / 11-14 Nm
14
Check valve
KN
Load sensing circuit, circle
endblue side steer cylinder
extend
8-10 ft-lbs / 11-14 Nm
15
Check valve
KO
Load sensing circuit, circle
endyellow side steer cylinder
extend
8-10 ft-lbs / 11-14 Nm
100
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Part No. 1268556
101
Service and Repair Manual
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Manifolds
Four Wheel Steer and Oscillate Manifold, continued
Index
Description
No.
Schematic
Function
Item
Torque
16
Solenoid valve, 3 position 4 way
KP
Steer left/right, circle endblue
side steer cylinder
26-30 ft-lbs / 35-41 Nm
17
Solenoid valve, 3 position 4 way
KQ
Steer left/right, circle endyellow
side steer cylinder
26-30 ft-lbs / 35-41 Nm
18
Flow regulator valve, 1.0 gpm / 3.8
L/min
KR
Square end, left side steer
cylinder retract circuit
20-25 ft-lbs / 27-34 Nm
19
Check valve
KS
Load sensing circuit, square
endblue side steer cylinder
retract
20-25 ft-lbs / 27-34 Nm
20
Check valve, 65 psi / 4.5 bar
KT
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
21
Check valve, 65 psi / 4.5 bar
KU
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
22
Flow regulator valve, 1.5 gpm / 5.7
L/min
KV
Square end, yellow side steer
cylinder extend circuit
20-25 ft-lbs / 27-34 Nm
23
Flow regulator valve, 1.0 gpm / 3.8
L/min
KW
Square end, yellow side steer
cylinder retract circuit
26-30 ft-lbs / 35-41 Nm
24
Flow regulator valve, 1.5 gpm / 5.7
L/min
KX
Square end, blue side steer
cylinder extend circuit
20-25 ft-lbs / 27-34 Nm
25
Check valve
KY
Load sensing circuit, square
endyellow side steer cylinder
retract
8-10 ft-lbs / 11-14 Nm
26
Check valve, 65 psi / 4.5 bar
KZ
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
27
Check valve, 65 psi / 4.5 bar
KAA
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
28
Check valve
KAB
Load sensing circuit, square
endyellow side steer cylinder
extend
8-10 ft-lbs / 11-14 Nm
29
Check valve
KAC
Load sensing circuit, square
endblue side steer cylinder
extend
8-10 ft-lbs / 11-14 Nm
30
Check valve, 65 psi / 4.5 bar
KAD
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
31
Check valve, 65 psi / 4.5 bar
KAE
Prevents steer cylinder from
moving when not steering
20-25 ft-lbs / 27-34 Nm
102
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Part No. 1268556
103
Service and Repair Manual
September 2016
Manifolds
How to Adj ust the Oscill ate R elief Val ve
How to Adjust the Oscillate Relief
Valve
Note: Perform this procedure with the boom in the
stowed position.
Note: This procedure will require two people.
Note: Refer to Oscillate Manifold Component list to
locate the oscillate relief valve.
1
Remove the drive chassis cover from the
square-end of the machine.
2
Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the two
wheel steer and oscillate manifold.
3
Start the engine from the platform controls.
4
Press down the foot switch and manually
activate one of the oscillate limit switches. Hold
the switch in the activated position and
observe the reading on the pressure gauge.
Refer to Specifications, Hydraulic Component
Specifications.
5
Turn the engine off. Use a wrench to hold the
relief valve and loosen the jam nut.
6
Adjust the stud with a hex wrench. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Tighten the jam nut.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7
Repeat steps 3 through 4 to confirm relief
valve pressure.
8
Remove the pressure gauge.
9
Install the drive chassis cover.
104
Part No. 1268556
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Service and Repair Manual
Manifolds
8-9
Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
Description
No.
Schematic
Function
Item
Torque
1
Pilot Operated Directional valve,
2 position 3 way
CBA
Activates generator
80-90 ft-lbs / 108-122 Nm
2
Orifice disc, 0.031 inch / 0.79 mm
CBB
Delays shift to drive
35-40 ft-lbs / 47-54 Nm
3
Solenoid valve, 2 position 3 way
CBC
Pilot valve to diverter
35-40 ft-lbs / 47-54 Nm
4
Relief valve, 280 psi @ 3.5 gpm /
19.3 bar @ 13.2 L/min
CBD
Charge pressure circuit
35-40 ft-lbs / 47-54 Nm
5
Pressure switch 200 psi / 18.6 bar
CBE
Generator relay switch
6
Connector fitting
7
Check valve
CBF
Prevents oil flowing into
generator
Part No. 1268556
16 ft-lbs / 22 Nm
11 ft-lbs / 15 Nm
35-40 ft-lbs / 47-54 Nm
105
Service and Repair Manual
September 2016
Manifolds
8-10
Traction Manifold Components, 2WD
The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.
Index
Description
No.
1
Check valve, 5 psi / 0.34 bar
2
3
Schematic
Function
Item
Torque
EA
Drive motor anti-cavitation
30-35 ft-lbs / 41-47 Nm
Check valve, 5 psi / 0.34 bar
EB
Drive motor anti-cavitation
30-35 ft-lbs / 41-47 Nm
Orifice, 0.031 in / 0.79 mm
EC
Brake and 2-speed circuit
4
Check valve
ED
Keeps brakes released in case of
temporary loss of charge
pressure
20-25 ft-lbs / 27-34 Nm
5
Solenoid valve, 2 position 3 way
EE
Brake release
26-30 ft-lbs / 35-41 Nm
6
Solenoid valve, 2 position 3 way
EF
2-speed drive motor shift
26-30 ft-lbs / 35-41 Nm
7
Relief valve, 280 psi / 19.3 bar
EG
Charge pressure circuit
20-25 ft-lbs / 27-34 Nm
8
Shuttle valve, 3 position 3 way
EH
Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump
30-35 ft-lbs / 41-47 Nm
9
Bi-directional flow control valve,
4.5 gpm / 17 L/min
EI
Equalizes pressure on both sides
of divider/combiner valve EJ
30-35 ft-lbs / 41-47 Nm
10
Flow divider/combiner valve
EJ
Controls flow to drive motors in
forward and reverse
90-100 ft-lbs / 122-136
Nm
106
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8-11
Valve Adjustments, 2WD Traction
Manifold
How to Adjust the Charge
Pressure Relief Valve
Note: Refer to 2WD Traction Manifold Component
list to locate the charge pressure relief valve.
Note: Perform this procedure with the hydraulic oil
temperature at 100°F to 150°F / 38°C to 65.5°C.
Note: This will take two people to perform this
procedure.
1
Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2
Start the engine from the ground controls.
3
Press the function enable/high rpm select
button (rabbit symbol) position. Note the
reading on the pressure gauge.
4
Turn the engine off.
5
Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the drive manifold.
6
Use a wrench to hold the charge pressure
relief valve and remove the cap.
7
Start the engine from the platform controls.
108
8
Move rpm select switch to high rpm (rabbit
symbol).
9
Begin driving the machine forward at a
medium speed while one person monitors the
pressure gauge. Continue driving until the
pressure stabilizes.
Note: The pressure reading should be
approximately 40 psi / 2.8 bar less than the
pressure reading taken in step 3.
10 If it is not, stop the machine and adjust the
internal hex socket on the pressure relief valve
either up or down.Turn it clockwise to increase
the pressure or counterclockwise to decrease
the pressure.
11 Drive the machine forward and check the
pressure.
12 Continue making small adjustments until the
pressure reading on the gauge is
approximately 40 psi / 2.8 bar less than the
pressure reading taken in step 3.
13 Turn the engine off and remove the pressure
gauge.
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Manifolds
8-12
Traction Manifold Components, 4WD
The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.
Index
Description
No.
1
Check valve, 5 psi / 0.34 bar
2
3
Schematic
Function
Item
Torque
FA
Drive motor anti-cavitation
30-35 ft-lbs / 41-47 Nm
Solenoid valve, 2 position 3 way
FB
2-speed drive motor shift
26-30 ft-lbs / 35-41 Nm
Solenoid valve, 2 position 3 way
FC
Brake release
26-30 ft-lbs / 35-41 Nm
4
Check valve
FD
Keeps brakes released in case
oftemporary loss of charge
pressure
20-25 ft-lbs / 27-34 Nm
5
Shuttle valve, 3 position 3 way
FE
Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump
30-35 ft-lbs / 41-47 Nm
6
Relief valve, 280 psi / 19.3 bar
FF
Charge pressure circuit
20-25 ft-lbs / 27-34 Nm
7
Orifice, 0.030 in / 0.76 mm
FG
Brake and 2-speed circuit
8
Check valve
FH
Drive motor anti-cavitation
20-25 ft-lbs / 27-34 Nm
9
Check valve
FI
Drive motor anti-cavitation
30-35 ft-lbs / 41-47 Nm
10
Flow divider/combiner valve
FJ
Controls flow to square end drive
motors in forward and reverse
90-100 ft-lbs / 122-136
Nm
11
Check valve, 5 psi / 0.34 bar
FK
Drive motor anti-cavitation
20-25 ft-lbs / 27-34 Nm
12
Bi-directional flow control
valve,2 gpm / 7.6 L/min
FL
Equalizes pressure on both sides
of divider/combiner valve FJ
30-35 ft-lbs / 41-47 Nm
13
Bi-directional flow control
valve,2 gpm / 7.6 L/min
FM
Equalizes pressure on both sides
of divider/combiner valve FQ
30-35 ft-lbs / 41-47 Nm
14
Bi-directional flow control
valve,2 gpm / 7.6 L/min
FN
Equalizes pressure on both sides
of divider/combiner valve FP
30-35 ft-lbs / 41-47 Nm
15
Check valve
FO
Drive motor anti-cavitation
20-25 ft-lbs / 27-34 Nm
16
Flow divider/combiner valve
FP
Controls flow to circle end drive
motors in forward and reverse
90-100 ft-lbs / 122-136
Nm
17
Flow divider/combiner valve
FQ
Controls flow to divider/combiner
valves FJ and FP
90-100 ft-lbs / 122-136
Nm
18
Check valve
FR
Drive motor anti-cavitation
20-25 ft-lbs / 27-34 Nm
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Manifolds
8-13
Valve Adjustments, 4WD Traction
Manifold
How to Adjust the Charge
Pressure Relief Valve
Note: Refer to 4WD Traction Manifold Component
list to locate the charge pressure relief valve.
Note: Perform this procedure with the hydraulic oil
temperature at 100°F to 150°F / 38°C to 65.5°C.
Note: This will take two people to perform this
procedure.
1
Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2
Start the engine from the ground controls.
3
Press the function enable/high rpm select
button (rabbit symbol) position. Note the
reading on the pressure gauge.
4
Turn the engine off.
5
Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the drive manifold.
6
Use a wrench to hold the charge pressure
relief valve and remove the cap.
7
Start the engine from the platform controls.
112
8
Move rpm select switch to high rpm (rabbit
symbol).
9
Begin driving the machine forward at a
medium speed while one person monitors the
pressure gauge. Continue driving until the
pressure stabilizes.
Note: The pressure reading should be
approximately 40 psi / 2.8 bar less than the
pressure reading taken in step 3.
10 If it is not, stop the machine and adjust the
internal hex socket on the pressure relief valve
either up or down.Turn it clockwise to increase
the pressure or counterclockwise to decrease
the pressure.
11 Drive the machine forward and check the
pressure.
12 Continue making small adjustments until the
pressure reading on the gauge is
approximately 40 psi / 2.8 bar less than the
pressure reading taken in step 3.
13 Turn the engine off and remove the pressure
gauge.
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Manifolds
8-14
Valve Coils
Valve Coil Resistance
Specification
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Since coil resistance is sensitive to temperature,
resistance values outside specification can produce
erratic operation. When coil resistance decreases
below specification, amperage increases. As
resistance rises above specification, voltage
increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1
Tag and disconnect the wiring from the coil to
be tested.
2
Test the coil resistance.
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 10°C
that your air temperature increases or decreases
from 68°F / 20°C.
Valve Coil Resistance Specification
Proportional solenoid valve, 12V DC
(schematic items G, W and AB)
4.8 Ω
Proportional solenoid valve, 12V DC
(schematic items R)
9Ω
3 position 4 way solenoid valve, 12V DC
(schematic items BA, BB, CA, CB, CP, CQ,GB,
GP and GQ)
9Ω
3 position 4 way solenoid valve, 10V DC
(schematic items O and S)
6.3 Ω
2 position 2 way solenoid valve, 10V DC
(schematic items J)
3.3 Ω
2 position 2 way solenoid valve, 10V DC
(schematic items C and P)
6.3 Ω
2 position 3 way solenoid valve, 10V DC
(schematic items H, V, X, Z, AA, EE and EF)
6.3 Ω
2 position 3 way solenoid valve, 12V DC
(schematic items BC, BD, CE, CF, FB and FC)
9Ω
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
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Manifolds
How to Test a Coil Diode
Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1
Test the coil for resistance. Refer to Repair
Procedure, How to Test a Coil.
2
Connect a 10W resistor to the negative
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a
terminal on the coil.
1
2
3
4
multimeter
9v DC battery
10Ω resistor
coil
Note: Dotted lines in illustration indicate a reversed
connection as specified in step 6.
Resistor 10Ω
3
Genie part number 27287
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.
Note: The battery should read 9V DC or more when
measured across the terminals.
Set a multimeter to read DC current.
4
Connect the negative lead to the other terminal
on the coil.
5
Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
DC battery. Note and record the current
reading.
6
At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
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Service and Repair Manual
Turntable Rotation Components
9-1
Turntable Rotation Assembly
How to Remove a Turntable
Rotation Assembly
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the primary boom
between the circle-end tires and with the machine
on a firm, level surface.
1
Secure the turntable from rotating with the
turntable rotation lock pin.
2
Remove the ground controls side fixed
turntable cover.
3
Tag, disconnect the hydraulic hoses from the
turntable rotation motor. Cap the fittings on the
motor.
5
Remove the drive hub mounting bolts and
remove the turntable rotation assembly from
the machine.
6
Repeat steps 3 through 5 for the other
turntable rotation assembly.
Tip-over hazard. If the turntable
rotation lock pin is not properly
installed, machine stability is
compromised and the machine
could tip over when the drive hub
is removed from the machine,
which could result in death or
serious injury.
Crushing hazard. The drive hub
could become unbalanced and
fall if not properly supported by an
overhead crane or lifting device
when removed from the machine.
Note: When installing a turntable rotation assembly,
the rotation gear backlash must be adjusted. Refer
to Repair Procedure, Adjust the Turntable Rotation
Gear Backlash.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4
Attach a lifting strap from an overhead crane or
other suitable lifting device to the lifting eye on
the turntable rotation assembly.
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Turntable Rotation Components
How to Adj ust the Tur ntabl e R otati on Gear Bac klash
How to Adjust the Turntable
Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor pinion gear and the turntable bearing
ring gear.
Note: Perform this procedure with the platform
between the circle-end tires and with the machine
on a firm, level surface.
1
Secure the turntable from rotating with the
turntable rotation lock pin.
2
Loosen the backlash pivot plate mounting
fasteners.
3
Push the backlash pivot plate towards the
turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4
Loosen the lock nut on the adjustment bolt.
5
Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6
Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
7
Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Torque the mounting fasteners on the
backlash pivot plate to specification. Refer to
Specifications, Machine Torque
Specifications.
8
Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
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Axle Components
10-1
Steer Sensors
he steer sensor measures steer angle and
communicates that information to the ground
controls ECM. The steer sensor on the ground
controls side of the machine at the square end acts
as the lead sensor. The other three sensors follow
the position, or steer angle, of the lead sensor.
There is a steer sensor mounted to the top of each
upper yoke pivot pin.
4
Measure the distance between the inside of
one circle-end tire and the chassis side plate
on both sides of the axle.
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Square-end
Measure here
Circle-end
Note: If the square-end steering function becomes
inoperative, switch to circle-end steer mode and the
ground controls side circle-end steer sensor will
become the lead sensor.
Note: This procedure will require a minimum of two
people.
How to M easur e the Tire Alignment
1
Start the engine from the platform controls.
Note: If the measurements are different or if a tire is
not parallel with the chassis, the steer sensor of that
tire will need to be adjusted. Refer to Repair
Procedure, How to Adjust a Steer Sensor.
2
Press down the foot switch.
5
How to Measure the Tire
Alignment
Repeat step 4 for the other circle-end tire.
Measure the circle-end tires:
Measure the square-end tires:
3
6
Press the circle-end steer mode button.
7
Measure the distance between the inside of
one square-end tire and the chassis side plate
on both sides of the axle.
Press the square-end steer mode button.
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Note: If the measurements are different or if a tire is
not parallel with the chassis, the steer sensor of that
tire will need to be adjusted. Refer to Repair
Procedure, How to Adjust a Steer Sensor.
8
Part No. 1268556
Repeat step 4 for the other square-end tire.
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Axle Components
How to Adj ust a Steer Sens or
How to Adjust a Steer Sensor
Circle-end steer sensors:
1
Start the engine from the platform controls.
2
Press down the foot switch and push the
engine idle select button until the engine
switches to high rpm.
10 At the platform controls, press the square-end
steer mode button.
Square-end steer sensors:
11 Locate the steer sensor on top of the yoke
pivot pin.
12 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
3
At the platform controls, press the circle-end
steer mode button.
4
Locate the steer sensor on top of the yoke
pivot pin.
13 Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
5
Loosen the steer sensor cover retaining
fasteners. Do not remove them.
14 Repeat step 4 until the tire is parallel with the
chassis.
6
Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
15 Tighten the steer sensor cover fasteners.
Square-end
Measure here
Circle-end
16 Repeat steps 9 through 13 for the other
circle-end steer sensor.
17 At the platform controls, press the four-wheel
steer mode button. Measure the distance
between the inside of the tire and the chassis
side plate on both sides of the axle on each
tire.
18 If any tire is not parallel, repeat the process
beginning with step 3.
7
Repeat step 4 until the tire is parallel with the
chassis.
8
Tighten the steer sensor cover fasteners.
9
Repeat steps 2 through 6 for the other
square-end steer sensor.
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Axle Components
How to C alibr ate the Steer Sens ors
How to Calibrate the Steer
Sensors
If a steer sensor reaches the limit of travel before a
tire is adjusted parallel to the chassis, the steer
sensor must be calibrated. This procedure will
re-establish a center position on the steer sensor.
Note: Perform this procedure with the machine in
the stowed position.
Note: This procedure will require two people.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
8
Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
9
Use the previous button to scroll through the
menu until the appropriate steer sensor is
displayed. Choose from:
RESET BLUE END BLUE SIDE STEER
SENSOR
RESET YELLOW END BLUE SIDE STEER
SENSOR
RESET YELLOW END YELLOW SIDE
STEER SENSOR
RESET BLUE END YELLOW SIDE STEER
SENSOR
Press the previous button to select YES, then
press the enter button.
Plus
Minus
Previous
Enter
1
Start the engine from the platform controls.
2
Press down the foot switch.
3
Choose a steer mode based on the tire that
needs alignment.
Note: If a circle-end tire cannot be aligned, press
the square-end steer mode button. If a square-end
tire cannot be aligned, press the circle-end steer
mode button.
4
Loosen the steer sensor cover retaining
fasteners. Do not remove them.
5
Rotate the steer sensor cover either clockwise
or counterclockwise to bring the tire as close to
alignment as possible.
6
Turn off the engine.
7
Press and hold the enter button on the ground
control panel while pulling out the ground
controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release it.
Part No. 1268556
10 Exit the sensor calibration mode and turn the
keyswitch to the off position.
11 Rotate the steer sensor to the opposite limit of
travel.
12 Using a voltmeter set to DC voltage, probe the
back of the steer sensor electrical connector at
pins B and C.
13 Turn the keyswitch on at the ground controls.
Rotate the sensor slowly until the voltage
reading is between 2.4 to 2.5V DC. The alarm
at the ground control box should sound.
14 Turn the keyswitch to platform controls. Start
the engine from the platform controls.
15 Press down the foot switch.
16 Rotate the steer sensor cover to adjust the tire
alignment. Measure the distance between the
inside of the tire and the chassis side plate on
both sides of the axle.
17 Repeat step 14 until the tire is parallel with the
chassis.
18 Tighten the steer sensor cover fasteners.
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Axle Components
How to Adj ust the Oscill ate Limit Swi tches
How to Adjust the Oscillate Limit
Switches
Tip-over hazard. Failure to
perform this procedure on a
firm, level surface could
compromise the stability of the
machine and could cause the
machine to tip over which will
result in death or serious injury.
Note: Perform this procedure with the machine on a
firm, level surface that is free of obstructions. Use a
digital level to confirm.
Note: This procedure will require two people.
1
Lower the boom to the stowed position.
2
Remove the drive chassis cover from the
circle-end of the machine.
3
Remove the oscillate axle limit switch
mounting fasteners. Remove the limit
switches.
7
Carefully hold the position of each limit switch
and tighten the limit switch mounting fasteners.
8
Verify the gap is 0.015 - 0.030 inches / 0.381 0.762 mm between the limit switch plunger
and the top of the axle.
9
Measure the distance between the drive
chassis and the axle on both sides (from the
inside of the drive chassis).
Result: The measurements should be equal.
Note: If the distance is not equal and the
adjustment to the limit switches was completed with
the ground and drive chassis level, consult Genie
Product Support.
Note: The oscillate axle limit switches are located
inside the drive chassis above the axle.
4
Place a digital level on the turntable rotate
bearing plate.
5
Start the engine and level the drive chassis.
Press down the foot switch and manually
activate the oscillate limit switches until the
machine is completely level.
6
Loosely install the limit switches. Using a feeler
gauge, establish a gap of 0.015 - 0.030 inches
/ 0.381 - 0.762 mm between the limit switch
plunger and the top of the axle.
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Axle Components
10-2
Oscillating Axle Cylinders
3
Remove the pin retaining fasteners from the
oscillate cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
The oscillating axle cylinders extend and retract
between the drive chassis and the oscillating axle.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure. The valves are not adjustable.
4
Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
5
Remove the pin retaining fasteners from the
oscillate cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
Crushing hazard. The oscillate
cylinder may become
unbalanced and fall when
removed from the machine if not
properly attached to the
overhead crane.
How to Remove an Oscillating
Axle Cylinder
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1
Rotate the boom until the turntable
counterweight is between the circle-end and
square-end tires.
2
Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on
the oscillate cylinder.
6
Remove the oscillate cylinder from the
machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
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Fault Codes
Section 4
Faul t Codes
Before Troubleshooting:
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
 Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine
 Immediately tag and remove from service a
damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
 Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
 Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
conditions.
 Be aware of the following hazards and follow
generally accepted safe workshop practices.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
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Control System Fault Codes
How to Read Control System
Fault Codes
Using Web GPI
1
Connect the device containing the WEB GPI
software to the TCON with an RS-232 cable.
2
Select the Secondary Boom, then the Safety
Switch Status Flags screen.
3
Change any safety switch drop down menus
displaying fault to ok. Press send.
4
Exit Web GPI.
Note: Initial fault testing occurs at power-up.
Faults are abnormal conditions that exist due to
component failure or System misuse. CPU,
memory, LCD, LED, limited joystick and limited
operator switch testing is done on power-up. If an
operator switch is depressed on power-up, the
display should show and error and not allow any
machine functions.
Using the TCON LCD
Releasing the switch will clear the error and allow
all machine functions. The joystick operates
similarly.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
All other fault testing is done continuously.
1
2
3
When a fualt is diagnosed, the PCON fault
indicator will flash and a fault message will be
displayed on the TCON LCD. The message
will contain the fault source and type.
Additional information, including the
occurrence counter and a time-stamp is
available with a PC, connected to one of the
RS232 ports. Up to 30 unique fault messages
can be saved. Each fault is saved with the
device identity, fault type, engine hour
time-stamp and an 8-bit occurrence counter.
The fault code table on the following pages
lists the functions or components monitored by
the system and recovery actions.
How to Clear Secondary Boom
Safety Switch Faults
Note: Beginning with software release 2.0, the
secondary boom envelope switches will latch and
faults must be reset in software or through the use
of the TCON LCD. They will not clear by
re-powering the machine.
Plus
Minus
Previous
Enter
Note: Take care when using this method to avoid
resetting threshold defaults.
1
With the key switch off, press and hold the
enter button and turn the key switch to the on
position. Release the enter button after five
seconds and then press the buttons in the
following sequence:
(minus)(minus)(previous)(previous).
2
Press the previous button until CLEAR ALL
SAFETY SWITCH FAULTS appears.
3
Select YES, then press the enter button.
4
Press the previous button until EXIT appears.
5
Select YES, then press the enter button.
Note: This clears all latching faults, not standard
faults.
Note: There are two methods to reset the faults, by
using Web GPI or through the menu available on
the TCON LCD.
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Control System Fault Codes
Error Source
Primary Up/Down Joystick
Error Type
Value at 5.0 V
Value Too High
Effects
Recovery Actions
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace and
recalibrate joystick.
Value Too Low
Value at 0 V
Primary Ext/Ret Joystick
Not calibrated
Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value at 5.0 V
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace and
recalibrate joystick.
Value Too High
Value Too Low
Value at 0 V
Primary Boom Up/Down
Flow Valve(s) (#1 and #2)
Not calibrated
Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Not calibrated
Normal function except threshold for
one or the other direction is zero.
Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value Too High
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
Not calibrated
Normal function except threshold for
one or the other direction is zero.
Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value Too High
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
Value Too Low
Primary Boom
Extend/Retract Flow Valve
Value Too Low
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Service and Repair Manual
Control System Fault Codes
Error Source
Error Type
Effects
Recovery Actions
Primary Up/Down Speed
Not calibrated
Display message on LCD and allow
operation at default speed
Perform auto calibrate procedure.
Primary Extend/Retract
Speed
Not calibrated
Display message on LCD and allow
operation at default speed
Perform auto calibrate procedure.
Primary Boom Up/Down
buttons on TCON
Fault Check (both
buttons pressed)
Primary Boom Up/Down disabled,
display message on LCD
Check ribbon and connector from
membrane switch. If necessary replace
membrane switch.
Primary Boom Extend Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Primary Boom Length
Fault Check
(unknown length)
Display message on LCD
Power up controller with problem
corrected.
Primary Boom Angle
Fault Check
(unknown length)
Allow only primary boom retract and
down. Display message on LCD.
Power up controller with problem
corrected.
Primary Boom Retract Valve
Primary Boom Up Valve
Primary Boom Down Valve
Primary Lock-Out Valve #1
Primary Lock-Out Valve #2
Primary Boom Angle Sensor Value at 5.0 V
Part No. 1268556
Sound audible warning and flash
Power up controller with problem
primary boom down LED at the
corrected.
medium rate and display message on
LCD screen PRI BOOM ANG SENSOR
SHORTED HIGH. Primary boom up
inhibited. Primary boom velocity limited
to 50% of default value.
Value at 0 V
Sound audible warning and flash
Power up controller with problem
primary boom down LED at the
corrected.
medium rate and display message on
LCD screen PRI BOOM ANG SENSOR
SHORTED LOW. Primary boom up
inhibited. Primary boom velocity limited
to 50% of default value.
Not calibrated
Sound audible warning at the medium
rate and display message on LCD
screen PRI BOOM ANG SENSOR
NOT CALIBRATED, inhibit primary
boom up from platform control.
Calibrate primary boom angle sensor.
Just calibrated
Initiate one second beep of audible
warning device.
Self-clearing (transient)
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Service and Repair Manual
September 2016
Control System Fault Codes
Error Source
Secondary Boom Joystick
Error Type
Value at 5.0 V
Value Too High
Effects
Recovery Actions
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace and
recalibrate joystick.
Value Too Low
Value at 0 V
Not calibrated
Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Secondary Boom
Down Sequence Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Down Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Extend Sequence Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Extend Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Retract Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Up Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Secondary Boom
Up/Down/Extend/Retract
Flow Valve
Not calibrated
Normal function except threshold for
one or the other direction is zero.
Display message on LCD
Perform calibration procedure
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value Too High
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
Value Too Low
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
126
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Service and Repair Manual
Control System Fault Codes
Error Source
Error Type
Effects
Recovery Actions
Secondary Boom Up/Down
Speed
Not calibrated
Display message on LCD and allow
operation at default speed
Secondary Boom
Up/Extend/Down/Retract
Switches on TCON
Fault Check (both
buttons pressed)
Secondary boom Up/Ext/Down/Retract Check ribbon and connector from
disabled Display message on LCD
membrane switch. If necessary replace
membrane switch.
Secondary Boom Length
Fault check
(unknown length)
Stop all secondary boom functions,
allow only secondary boom retract.
Display message on LCD.
Power up controller with problem
corrected.
Secondary Boom Angle
Fault check
(unknown length)
Stop all secondary boom functions,
allow only secondary boom retract.
Once the boom is retracted allow
secondary boom down. Display
message on LCD.
Power up controller with problem
corrected.
Turntable Rotate Joystick
Value at 5.0 V
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace and
recalibrate joystick.
Value Too High
Value Too Low
See service manual on how to perform
this procedure.
Value at 0 V
Not calibrated
Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Normal function except threshold for
one or the other direction is zero.
Display message on LCD
Perform calibration procedure
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value Too High
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
Turntable Rotate Flow Valve Not calibrated
Value Too Low
Check for shorts to ground in the
wiring. Replace coil if necessary
Turntable Rotate Buttons on
TCON
Fault Check (both
buttons pressed)
Turntable rotate disabled Display
message on LCD
Check ribbon and connector from
membrane switch. If necessary replace
membrane switch.
Turntable Rotate Clockwise
Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Not calibrated
Display message on LCD and allow
operation at default speed
Perform auto calibrate procedure.
Turntable Rotate
Counterclockwise Valve
Turntable Rotate Speed
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Control System Fault Codes
Error Source
Steer Joystick
Error Type
Value at 5.0 V
Value Too High
Effects
Recovery Actions
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace and
recalibrate joystick.
Value Too Low
Value at 0 V
Propel Joystick
Not calibrated
Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Value at 5.0 V
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Value Too High
Value Too Low
Self-clearing (transient)
Check for damaged wiring to the
joystick. Check the connections to
ensure the connector terminals have
not backed out. Substitute a known
good joystick. If necessary replace
and recalibrate joystick.
Value at 0 V
Not calibrated
Joystick Speed and Direction frozen at Calibrate Thresholds
zero and neutral
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Axle Extend/Retract Buttons
Fault Check (both
buttons pressed)
Steer Valves - LF, RF, LR,
RR
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Propel Valves
Forward/Reverse
Not calibrated
Joystick Speed and Direction frozen at Calibrate Thresholds
zero and neutral
Propel EDC
Forward/Reverse
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing (transient)
Value Too High
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for opens in the wiring or a bad
ground. Replace coil if necessary
Value Too Low
128
Axle extend/retract disabled. Display
message on LCD
Check ribbon and connector from
membrane switch. If necessary replace
membrane switch.
Check for defective or damaged
wiring. Check for an open or shorted
valve coil. Repair or replace as
necessary.
Check for shorts to ground in the
wiring. Replace coil if necessary
Part No. 1268556
September 2016
Service and Repair Manual
Control System Fault Codes
Error Source
Motor Valve Speed
Error Type
Fault Check
Effects
Recovery Actions
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Check for defective or damaged
wiring. Check for an open or shorted
valve coil. Repair or replace as
necessary.
Brake Valve
Auxiliary Propel Valve
Fault Check
Platform Level Up/Down and Fault Check
Rotate Valves
Fault Check
Check for defective or damaged wiring.
Check for an open or shorted valve coil.
Repair or replace as necessary.
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with problem
corrected.
Platform Rotate Switches
Fault Check, (both Affected functions disabled, display
contacts closed)
message on LCD.
Power up controller with problem
corrected.
Jib Boom Switches
Fault Check, (both Affected functions disabled, display
contacts closed)
message on LCD.
Power up controller with problem
corrected.
Jib Boom Up/Down Valves
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with problem
corrected.
Value at 5.0 V
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with problem
corrected.
Display message on LCD and sound
audible alarm.
Correct problem.
Steer Angle Sensor(s)
Right Front
Left Front
Right Rear
Left Rear
Turntable Level Sensor
X-Direction
Value Too High
Value Too Low
Value at 0 V
Fault Check
Turntable Level Sensor
Y-Direction
Platform Level Sensor
Y-Direction
Footswitch Timeout
Calibration check
CAN Bus
Fault Check
Display message on LCD
Oil Pressure
Range Check (low Display message on LCD
oil pressure)
Oil pressure is low. Check sender and
oil level.
Water/Oil Temperature
Range Check
(high temp)
Display message on LCD
Engine is overheating. Check sender,
water or oil level or radiator/heat
exchanger.
Oil Pressure Sender
Fault Check
Display message on LCD
Check wiring to senders for opens or
shorts. Repair or replace senders.
Range Check
(underspeed)
Display message on LCD
Power up controller with problem
corrected.
Display message on LCD
Recycle power
Power up controller with problem
corrected.
Water/Oil Temp Sender
Engine Speed
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Control System Fault Codes
Error Source
Error Type
Effects
Recovery Actions
Safety Switch P3
Fault Check
Display message on LCD
P3 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P6R1
Fault Check
Display message on LCD
P6R1 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P6R2
Fault Check
Display message on LCD
P6R2 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P7
Fault Check
Display message on LCD
P7 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P7R
Fault Check
Display message on LCD
P7R SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P9A
Fault Check
Display message on LCD
P9A SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P9B
Fault Check
Display message on LCD
P9B SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P10
Fault Check
Display message on LCD
P10 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P11
Fault Check
Display message on LCD
P11 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P12
Fault Check
Display message on LCD
P12 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P14
Fault Check
Display message on LCD
P14 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P18
Fault Check
Display message on LCD
P18 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P22
Fault Check
Display message on LCD
P22 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P22R
Fault Check
Display message on LCD
P22R SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Safety Switch P30
Fault Check
Display message on LCD
P30 SAFETY SWITCH FAULT
Power up controller with problem
corrected.
Platform Overload
Fault Check
(if active)
Display message on LCD
Power up controller with problem
corrected.
Fault Check
(if active)
Display message on LCD
Power up controller with problem
corrected.
Platform Overload Switches
Inconsistent
Boom Overload
130
Part No. 1268556
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Service and Repair Manual
Fault Code Display - Deutz and Perkins Models
How to R etrieve Ac ti ve Engine F ault Codes D eutz D 2.9 L4 and Per ki ns 404F- 22 Models
How to Retrieve Active Engine
Fault Codes - Deutz D 2.9 L4 and
Perkins 404F-22 Models
The ECM constantly monitors the engine by the use
of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of set
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor. The
active fault code will also be displayed on the LCD
screen.
Note: The Perkins 404F-22T is equipped with an
engine fault LED located at the platform control
box.
If an engine fault occurs that does not result in an
engine shutdown, the engine rpm will go into limp
home mode resulting in the loss of high rpm..
Start the engine from the ground control box and
operate various boom functions to verify that an
active engine fault occurs and is shown on the
display.
Note: All faults are stored in the Previous Fault
history menu. These faults will not be erased when
corrective action has been completed.
Note: Software is available from the engine
manufacturer to perform diagnosis through the
engine diagnostic port. Contact the specific engine
manufacturer.
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Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI
KWP
Description
51
11
1231
Actuator error EGR-Valve; Power
stage over temp due to high
current
SPN FMI
KWP
Description
51
12
1018
51
3
1019
EGR-Valve, short circuit to
battery
Actuator EGR-Valve; powerstage
over temperature
51
12
1021
51
3
1024
Position sensor error of actuator
EGR-Valve; signal range check
high
Mechanical actuator defect
EGR-Valve
51
12
1225
Actuator EGR-Valve; over
temperature
51
3
1226
EGR-Valve; short circuit to
battery (A02)
94
1
474
Low fuel pressure; warning
threshold exceeded
51
3
1227
EGR-Valve; short circuit to
battery (A67)
94
1
475
Low fuel pressure; shut off
threshold exceeded
51
4
1020
EGR-Valve; short circuit to
ground
94
3
472
Sensor error low fuel pressure;
signal range check high
51
4
1025
Position sensor error actuator
EGR-Valve; signal range check
low
94
4
473
Sensor error low fuel pressure;
signal range check low
51
4
1228
EGR-Valve; short circuit to
ground (A02)
97
3
464
Sensor error water in fuel; signal
range check high
51
4
1229
EGR-Valve; short circuit to
ground (A67)
97
4
465
Sensor error water in fuel; signal
range check low
1
4
1232
Actuator error EGR-Valve;
Voltage below threshold
97
12
1157
Water in fuel level prefilter;
maximum value exceeded
51
5
1015
Actuator error EGR-Valve; signal
range check low
100
0
734
High oil pressure; warning
threshold exceeded
51
5
1017
Actuator EGR-Valve; open load
100
0
735
High oil pressure; shut off
threshold exceeded
51
5
1023
Actuator error EGR-Valve; signal
range check low
100
1
736
Low oil pressure; warning
threshold exceeded
51
5
1223
Actuator EGR-Valve; open load
100
1
737
51
6
1014
Actuator error EGR-Valve; signal
range check high
Low oil pressure; shut off
threshold exceeded
100
3
732
51
6
1022
Actuator error EGR-Valve; signal
range check high
Sensor error oil pressure; signal
range check high
100
4
733
51
6
1224
Actuator EGR-Valve; over
current
Sensor error oil pressure sensor;
signal range check low
102
2
88
51
6
1230
Actuator error EGR-Valve;
Overload by short-circuit
Charged air pressure above
warning threshold
102
2
89
51
7
1016
Actuator position for EGR-Valve
not plausible
Charged air pressure above shut
off threshold
102
4
777
Sensor error charged air press.;
signal range check low
132
Part No. 1268556
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Service and Repair Manual
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI
KWP
Description
168
0
1180
Physical range check high for
battery voltage
SPN FMI
KWP
Description
168
1
1181
105
996
High charged air cooler
temperature; warning threshold
exceeded
Physical range check low for
battery voltage
168
2
47
High battery voltage; warning
threshold exceeded
168
2
48
Low battery voltage; warning
threshold exceeded
168
3
45
Sensor error battery voltage;
signal range check high
168
4
46
Sensor error battery voltage;
signal range check low
171
3
417
Sensor error environment
temperature; signal range check
high
171
4
418
Sensor error environment
temperature; signal range check
low
172
0
1182
Physical range check high for
intake air temperature
172
1
1183
Physical range check low for
intake air temperature
172
2
9
Sensor ambient air temperature;
plausibility error
172
2
983
Intake air sensor; plausibility
error
172
3
981
Sensor error intake air; signal
range check high
172
4
982
Sensor error intake air sensor;
signal range check low
174
0
481
High low fuel temperature;
warning threshold exceeded
174
0
482
High Low fuel temperature; shut
off threshold exceeded
175
0
740
Physical range check high for oil
temperature
175
0
745
High oil temperature; warning
threshold exceeded
175
0
746
High oil temperature; shut off
threshold exceeded
175
1
741
Physical range check low for oil
temperature
0
105
0
997
High charged air cooler
temperature; shut off threshold
exceeded
105
3
994
Sensor error charged air
temperature; signal range check
high
105
4
995
Sensor error charged air
temperature; signal range check
low
108
3
412
Sensor error ambient air press.;
signal range check high
108
4
413
Sensor error ambient air press.;
signal range check low
110
0
98
High coolant temperature;
warning threshold exceeded
110
0
99
High coolant temperature; shut
off threshold exceeded
110
3
96
Sensor error coolant temp.;
signal range check high
110
4
97
Sensor error coolant temp.;
signal range check low
111
1
101
Coolant level too low
132
11
1
Air flow sensor load correction
factor exceeding the maximum
drift limit; plausibility error
132
11
2
Air flow sensor load correction
factor exceeding drift limit;
plausibility error
132
11
3
Air flow sensor low idle correction
factor exceeding the maximum
drift limit
132
11
4
Air flow sensor load correction
factor exceeding the maximum
drift limit
157
3
877
Sesnor error rail pressure; signal
range check high
157
4
878
Sensor error rail pressure; signal
range check low
Part No. 1268556
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Service and Repair Manual
September 2016
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI
KWP
Description
412
3
1007
Sensor error EGR cooler
downstream temperature; signal
range check high
412
4
1008
Sensor error EGR cooler
downstream temperature; signal
range check low
SPN FMI
KWP
Description
175
2
738
Sensor oil temperature;
plausibility error
175
2
739
Sensor oil temperature;
plausibility error oil temperature
too high
520
9
306
175
3
743
Sensor error oil temperature;
signal range check high
Timeout Error of
CAN-Receive-Frame TSC1TR;
Setpoint
597
2
49
175
4
744
Sensor error oil temperature;
signal range check low
Break lever mainswitch and
break lever redundancy switch
status not plausible
190
0
389
Engine speed above warning
threshold (FOC-Level 1)
624
3
971
SVS lamp; short circuit to batt.
624
4
972
SVS lamp; short circuit to grd.
190
2
421
Offset angle between crank- and
camshaft sensor is too large
624
5
969
SVS lamp; open load
624
12
970
SVS lamp; powerstage over
temperature
190
8
419
Sensor camshaft speed;
disturbed signal
630
12
376
190
8
422
Sensor crankshaft speed;
disturbed signal
Access error EEPROM memory
(delete)
630
12
377
Engine speed above warning
threshold (FOC-Level 2)
Access error EEPROM memory
(read)
630
12
378
Access error EEPROM memory
(write)
190
11
390
190
12
420
Sensor camshaft speed; no
signal
639
14
84
CAN-Bus 0 "BusOff-Status"
190
12
423
Sensor crankshaft speed; no
signal
651
3
580
Injector 1 (in firing order); short
circuit
190
14
391
Engine speed above warning
threshold (Overrun Mode)
651
4
586
High side to low side short circuit
in the injector 1 (in firing order)
190
14
1222
Camshaft- and Crankshaft speed
sensor signal not available on
CAN
651
5
568
Injector 1 (in firing order);
interruption of electric connection
652
3
581
411
0
791
Physical range check high for
differential pressure Venturiunit
(EGR)
Injector 2 (in firing order); short
circuit
652
4
587
High side to low side short circuit
in the injector 2 (in firing order)
652
5
569
Injector 2 (in firing order);
interruption of electric connection
653
3
582
Injector 3 (in firing order); short
circuit
653
4
588
High side to low side short circuit
in the injector 3 (in firing order)
653
5
570
Injector 3 (in firing order);
interruption of electric connection
411
1
792
Physical range check low for
differential pressure Venturiunit
(EGR)
411
3
795
Sensor error differential pressure
Venturiunit (EGR); signal range
check high
411
411
134
4
4
381
796
Physical range check low for
EGR differential pressure
Sensor error differential pressure
Venturiunit (EGR); signal range
check low
Part No. 1268556
September 2016
Service and Repair Manual
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI
KWP
Description
1109 2
121
Engine shut off demand ignored
1136 0
1398
Physikal range check high for
ECU temperature
SPN FMI
KWP
Description
654
3
583
Injector 4 (in firing order); short
circuit
1136 1
1399
Physikal range check low for
ECU temperature
654
4
589
High side to low side short circuit
in the injector 4 (in firing order)
1136 3
1400
Sensor error ECU temperature;
signal range check high
654
5
571
Injector 4 (in firing order);
interruption of electric connection
1136 4
1401
Sensor error ECU temperature;
signal range check low
676
11
543
Cold start aid relay error.
1176 3
849
676
11
544
Cold start aid relay open load
677
3
956
Starter relay high side; short
circuit to battery
Sensor error pressure sensor
upstream turbine; signal range
check high
1176 4
850
677
3
960
Starter relay low side; short
circuit to battery
Sensor error pressure sensor
downstream turbine; signal range
check high
677
4
957
Starter relay high side; short
circuit to ground
1180 0
1193
Physical range check high for
exhaust gas temperature
upstream turbine
677
4
961
Starter relay low side; short
circuit to ground
1180 0
1460
677
5
958
Starter relay; no load error
Turbocharger Wastegate CAN
feedback; warning threshold
exceeded
677
12
959
Starter relay; powerstage over
temperature
1180 0
1462
703
3
426
Engine running lamp; short circuit
to battery
Exhaust gas temperature
upstream turbine; warning
threshold exceeded
1180 1
1194
703
4
427
Engine running lamp; short circuit
to ground
Physical range check low for
exhaust gas temperature
upstream turbine
703
5
424
Engine running lamp; open load
1180 1
1461
703
12
425
Engine running lamp;
powerstage over temperature
Turbocharger Wastegate CAN
feedback; shut off threshold
exceeded
1180 1
1463
729
5
545
Cold start aid relay open load
729
12
547
Cold start aid relay; over
temperature error
Exhaust gas temperature
upstream turbine; shut off
threshold exceeded
1180 3
1067
Timeout Error of
CAN-Receive-Frame TSC1TE;
Setpoint
Sensor error exhaust gas
temperature upstream turbine;
signal range check high
1180 11
1066
Sensor exhaust gas temperature
upstream turbine; plausibility
error
1188 2
1414
Wastegate; status message from
ECU missing
898
9
305
1079 13
946
Sensor supply voltage monitor
1 error (ECU)
1080 13
947
Sensor supply voltage monitor
2 error (ECU)
Part No. 1268556
135
Service and Repair Manual
September 2016
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI
KWP
Description
2659 2
1527
AGS sensor temperature exhaust
gas mass flow; plausibility error
SPN FMI
KWP
Description
2659 12
1526
1188 7
1415
Wastegate actuator; blocked
1188 11
1411
Wastegate actuator; internal
error
Exhaust gas recirculation; AGS
sensor has "burn off" not
performed
2797 4
1337
1188 11
1412
Wastegate actuator; EOL
calibration not performed
correctly
Injector diagnostics; timeout error
of short circuit to ground
measurement cyl. Bank 0
2798 4
1338
Injector diagnostics; timeout error
of short circuit to ground
measurement cyl. Bank 1
2798 4
1339
Injector diagnostics; short circuit
to ground monitoring Test in Cyl.
Bank 0
1188 11
1416
Wastegate actuator; over
temperature (> 145øC)
1188 11
1417
Wastegate actuator; over
temperature (> 135øC)
1188 11
1418
Wastegate actuator; operating
voltage error
2798 4
1340
1188 13
1413
Wastegate actuator calibration
deviation too large, recalibration
required
Injector diagnostics; short circuit
to ground monitoring Test in Cyl.
Bank 1
3224 2
127
DLC Error of
CAN-Receive-Frame AT1IG1
NOX Sensor (SCR-system
upstream cat; DPF-system
downstream cat); length of frame
incorrect
3224 9
128
Timeout Error of
CAN-Receive-Frame AT1IG1;
NOX sensor upstream
3248 4
1047
Sensor error particle filter
downstream temperature; signal
range check low
3699 2
1616
DPF differential pressure sensor
and a further sensor or actuator
CRT system defective
1231 14
85
CAN-Bus 1 "BusOff-Status"
1235 14
86
CAN-Bus 2 "BusOff-Status"
1237 2
747
Override switch; plausibility error
1322 12
610
Too many recognized misfires in
more than one cylinder
1323 12
604
Too many recognized misfires in
cylinder 1 (in firing order)
1324 12
605
Too many recognized misfires in
cylinder 2 (in firing order)
1325 12
606
Too many recognized misfires in
cylinder 3 (in firing order)
1326 12
607
Too many recognized misfires in
cylinder 4 (in firing order)
3699 2
1617
Temperature sensor us. and ds.
DOC simultaneously defect
2659 0
1524
Physical range check high for
EGR exhaust gas mass flow
3699 14
1615
Maximum stand-still-duration
reached; oil exchange required
2659 1
1525
Physical range check low for
EGR exhaust gas mass flow
4765 0
1039
2659 2
1523
Exhaust gas recirculation AGS
sensor; plausibility error
Physical range check high for
exhaust gas temperature
upstream (DOC)
4765 1
1042
Physical range check low for
exhaust gas temperature
upstream (DOC)
136
Part No. 1268556
September 2016
Service and Repair Manual
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523212
9
171
Timeout Error of
CAN-Receive-Frame
ComEngPrt; Engine Protection
523216
9
198
Timeout Error of
CAN-Receive-Frame
PrHtEnCmd; pre-heat command,
engine command
SPN
FMI KWP Description
4766
0
1029 Physical range check high for
exhaust gas temperature
downstream (DOC)
4766
1
1032 Physical range check low for
exhaust gas temperature
downstream (DOC)
523240
9
179
4768
2
1036 Sensor exhaust gas temperature
upstream (DOC); plausibility
error
Timeout CAN-message
FunModCtl; Function Mode
Control
523350
4
565
Injector cylinder-bank 1; short
circuit
4768
3
1044 Sensor error exhaust gas
temperature upstream (DOC);
signal range check high
523352
4
566
Injector cylinder-bank 2; short
circuit
523354
12
567
Injector powerstage output defect
4768
4
1045 Sensor error exhaust gas
temperature upstream (DOC)
signal range check low
523470
2
826
Pressure Relief Valve (PRV)
forced to open; performed by
pressure increase
4769
2
1026 Sensor exhaust gas temperature
downstream (DOC); plausibility
error
523470
2
827
Pressure Relief Valve (PRV)
forced to open; performed by
pressure shock
4769
3
1034 Sensor error exhaust gas
temperature downstream (DOC);
signal range check high
523470
7
876
Maximum rail pressure in limp
home mode exceeded (PRV)
523470
11
831
4769
4
1035 Sensor error exhaust gas
temperature downstream (DOC);
signal range check low
The PRV can not be opened at
this operating point with a
pressure shock
523470
11
832
523006
3
34
Controller mode switch; short
circuit to battery
Rail pressure out of tolerance
range
523470
12
828
523006
4
35
Controller mode switch; short
circuit to ground
Open Pressure Relief Valve
(PRV); shut off condition
523470
12
829
523008
1
648
Manipulation control was
triggered
Open Pressure Relief Valve
(PRV); warning condition
523470
14
830
523008
2
649
Timeout error in Manipulation
control
Pressure Relief Valve (PRV) is
open
523550
12
980
523009
9
825
Pressure Relief Valve (PRV)
reached maximun allowed
opening count
T50 start switch active for too
long
523601
13
948
Sensor supply voltage monitor
3 error (ECU)
523603
9
126
Timeout Error of
CAN-Receive-Frame AMB;
Ambient Temperature Sensor
523009
10
833
Part No. 1268556
Pressure relief valve (PRV)
reached maximun allowed open
time
137
Service and Repair Manual
September 2016
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523605
9
523606
9
300
301
SPN
FMI KWP Description
523612
12
637
Internal ECU monitoring
detection reported error
523612
12
1170 Internal software error ECU
Timeout Error of
CAN-Receive-Frame TSC1AE;
Traction Control
523612
14
973
Softwarereset CPU SWReset_0
523612
14
974
Softwarereset CPU SWReset_1
Timeout Error of
CAN-Receive-Frame TSC1AR;
Retarder
523612
14
975
Softwarereset CPU SWReset_2
523613
0
856
Maximum positive deviation of
rail pressure exceeded
(RailMeUn0)
523613
0
857
Maximum positive deviation of
rail pressure in metering unit
exceeded (RailMeUn1)
523612
12
387
Internal software error ECU;
injection cut off
523612
12
612
Internal ECU monitoring
detection reported error
523612
12
613
Internal ECU monitoring
detection reported error
523613
0
858
Railsystem leakage detected
(RailMeUn10)
523612
12
614
Internal ECU monitoring
detection reported error
523613
0
859
523612
12
615
Internal ECU monitoring
detection reported error
Maximum negative deviation of
rail pressure in metering unit
exceeded (RailMeUn2)
523613
0
860
Negative deviation of rail
pressure second stage
(RailMeUn22)
523613
0
862
Maximum rail pressure exceeded
(RailMeUn4)
523613
1
861
Minimum rail pressure exceeded
(RailMeUn3)
523613
2
864
Setpoint of metering unit in
overrun mode not plausible
523615
3
594
Metering unit (Fuel-System);
short circuit to battery highside
523615
3
596
Metering unit (Fuel-System);
short circuit to battery low side
523615
4
595
Metering unit (Fuel-System);
short circuit to ground high side
523615
4
597
Metering Unit (Fuel-System);
short circuit to ground low side
523615
5
592
Metering unit (Fuel-System);
open load
523615
12
593
Metering unit (Fuel-System);
powerstage over temperature
523619
2
488
Physical range check high for
exhaust gas temperature
upstrem (SCR-CAT)
523698
11
122
Shut off request from supervisory
monitoring function
523612
12
616
Internal ECU monitoring
detection reported error
523612
12
617
Internal ECU monitoring
detection reported error
523612
12
618
Internal ECU monitoring
detection reported error
523612
12
619
Internal ECU monitoring
detection reported error
523612
12
620
Internal ECU monitoring
detection reported error
523612
12
621
Internal ECU monitoring
detection reported error
523612
12
623
Internal ECU monitoring
detection reported error
523612
12
624
Internal ECU monitoring
detection reported error
523612
12
625
Internal ECU monitoring
detection reported error
523612
12
627
Internal ECU monitoring
detection reported error
523612
12
628
Internal ECU monitoring
detection reported error
138
Part No. 1268556
September 2016
Service and Repair Manual
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523788
12
299
Timeout Error of
CAN-Transmit-Frame TrbCH;
Status Wastegate
523793
9
202
Timeout Error of
CAN-Receive-Frame UAA10;
AGS sensor service message
523794
9
203
Timeout Error of
CAN-Receive-Frame UAA11;
AGS sensor data
523895
13
559
Check of missing injector
adjustment value programming
(IMA) injector 1 (in firing order)
523896
13
560
check of missing injector
adjustment value programming
(IMA) injector 2 (in firing order)
SPN
FMI KWP Description
523717
12
125
523718
3
1488 SCR mainrelay; short circuit to
battery (only CV56B)
523718
4
1489 SCR mainrelay; short circuit to
ground (only CV56B)
523718
5
1486 SCR mainrelay; open load (only
CV56B)
523718
12
1487 SCR mainrelay; powerstage over
temperature (only CV56B)
523766
9
281
Timeout Error of
CAN-Receive-Frame Active
TSC1AE
523897
13
561
check of missing injector
adjustment value programming
(IMA) injector 3 (in firing order)
523767
9
282
Timeout Error of
CAN-Receive-Frame Passive
TSC1AE
523898
13
562
check of missing injector
adjustment value programming
(IMA) injector 4 (in firing order)
523768
9
283
Timeout Error of
CAN-Receive-Frame Active
TSC1AR
523910
6
1261 Air Pump; over current
523913
3
74
Timeout Error of
CAN-Receive-Frame Passive
TSC1AR
Sensor error glow plug control
diagnostic line voltage; signal
range check high
523913
4
75
Timeout Error of
CAN-Receive-Frame Passive
TSC1DE
Sensor error glow plug control
diagnostic line voltage; signal
range check low
523914
3
78
Glow plug control; short circuit to
battery
523914
4
79
Glow plug control; short circuit to
ground
Glow plug control; open load
523769
523770
9
9
284
285
Timeout Error of
CAN-Transmit-Frame AmbCon;
Weather environments
523776
9
291
Timeout Error of
CAN-Receive-Frame TSC1TE active
523777
9
292
Passive Timeout Error of
CAN-Receive-Frame TSC1TE;
Setpoint
523914
5
76
523914
5
1216 Glow plug control release line;
short circuit error
523914
11
1217 Glow plug control; internal error
523914
12
77
523919
2
1378 Sensor air pump airpressure;
plausibility error
523920
2
1379 Sensor exhaust gas back
pressure burner; plausibility error
523778
9
293
Active Timeout Errorof
CAN-Receive-Frame TSC1TR
523779
9
294
Passive Timeout Error of
CAN-Receive-Frame TSC1TR
Part No. 1268556
Glow plug control; powerstage
over temperature
139
Service and Repair Manual
September 2016
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523922
7
1262 Burner Shut Off Valve; blocked
closed
523922
7
1264 Burner Shut Off Valve; blocked
closed
523929
0
109
523929
523930
523930
523931
523931
523932
1
0
1
0
1
0
115
110
116
111
117
112
SPN
FMI KWP Description
523946
1
1164 Zero fuel calibration injector 1 (in
firing order); minimum value
exceeded
523947
0
1159 Zerofuel calibration injector 2 (in
firing order); maximum value
exceeded
523947
1
Fuel Balance Control integrator
injector 1 (in firing order);
maximum value exceeded
1165 Zerofuel calibration injector 2 (in
firing order); minimum value
exceeded
523948
0
Fuel Balance Control integrator
injector 1 (in firing order);
minimum value exceeded
1160 Zerofuel calibration injector 3 (in
firing order); maximum value
exceeded
523948
1
Fuel Balance Control integrator
injector 2 (in firing order);
maximum value exceeded
1166 Zerofuel calibration injector 3 (in
firing order); minimum value
exceeded
523949
0
Fuel Balance Control integrator
injector 2 (in firing order);
minimum value exceeded
1161 Zerofuel calibration injector 4 (in
firing order); maximum value
exceeded
523949
1
Fuel Balance Control integrator
injector 3 (in firing order);
maximum value exceeded
1167 Zerofuel calibration injector 4 (in
firing order); minimum value
exceeded
523960
0
Fuel Balance Control integrator
injector 3 (in firing order);
minimum value exceeded
1011 Physical range check high for
EGR cooler downstream temp.
523960
0
Fuel Balance Control integrator
injector 4 (in firing order);
maximum value exceeded
1458 High exhaust gas temperature
EGR cooler downstream;
warning threshold exceeded
523960
1
1012 Physical range check low for
EGR cooler downstream temp.
523932
1
118
Fuel Balance Control integrator
injector 4 (in firing order);
minimum value exceeded
523960
1
1459 High exhaust gas temperature
EGR cooler downstream; shut off
threshold exceeded
523935
12
168
Timeout Error of
CAN-Transmit-Frame
EEC3VOL1; Engine send
messages
523980
14
1187 Bad quality of reduction agent
detected
523981
11
918
Urea-tank without heating
function (heating phase)
Timeout Error of
CAN-Transmit-Frame
EEC3VOL2; Engine send
messages
523982
0
360
Powerstage diagnosis disabled;
high battery voltage
523982
1
361
Powerstage diagnosis disabled;
low battery voltage
523936
523946
140
12
0
169
1158 Zero fuel calibration injector 1 (in
firing order); maximum value
exceeded
Part No. 1268556
September 2016
Service and Repair Manual
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
524032
2
1442 EGR actuator; status message
EGRCust is missing
SPN
FMI KWP Description
524033
7
523988
3
1245 Charging lamp; short circuit to
battery
1443 EGR actuator; due to overload in
Save Mode
524034
3
523988
4
1246 Charging lamp; short circuit to
ground
1438 Disc separator; short circuit to
battery
524034
4
523988
5
1243 Charging lamp; open load
1439 Disc separator; short circuit to
ground
523988
12
1244 Charging lamp; over temp.
524034
5
1436 Disc Separator; open load
523998
4
1327 Injector cylinder bank 2 slave;
short circuit
524034
12
1437 Disc Separator; powerstage over
temperature
523999
12
1328 Injector powerstage output Slave
defect
524035
12
1341 Injector diagnostics; time out
error in the SPI communication
524014
1
1254 Air pressure glow plug flush line;
below limit
524057
2
1505 Electric fuel pump; fuel pressure
build up error
524016
2
1259 Amount of air is not plausible to
pump speed
524097
9
524016
2
1260 Calculated amount of air is not
plausible to HFM reading
1663 Timeout error of
CAN-Transmit-Frame
DPFBrnAirPmpCtl
524098
9
1664 Timeout error of
CAN-Transmit-Frame
ComDPFBrnPT
524099
9
1665 Timeout error of
CAN-Transmit-Frame
ComDPFC1
524100
9
1666 Timeout error of
CAN-Transmit-Frame
ComDPFHisDat
524101
9
1667 Timeout error of
CAN-Transmit-Frame
ComDPFTstMon
524016
11
1258 HFM sensor; electrical fault
524021
11
1263 Burner fuel line pipe leak behind
Shut Off Valve
524024
11
1302 Deviation of the exhaust gas
temp. setpoint to actual value
downstream (DOC) too high
524028
2
1431 CAN message PROEGRActr;
plausibility error
524029
2
1432 Timeout Error of
CAN-Receive-Frame
ComEGRActr - exhaust gas
recirculation positioner
524030
7
1440 EGR actuator; internal error
524031
13
1441 EGR actuator; calibration error
Part No. 1268556
141
Service and Repair Manual
September 2016
Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI
524102 9
KWP Description
1674 Timeout error of
CAN-Receive-Frame
ComRxDPFBrnAirPmpCtl
524103 9
1675 Timeout error of
CAN-Receive-Frame
ComRxDPFBrnAirPmp
524104 9
1676 Timeout error of
CAN-Receive-Frame
ComRxDPFCtl
524105 9
1668 Timeout error of
CAN-Transmit-Frame
ComEGRMsFlw
524106 9
1677 Timeout error of
CAN-Receive-Frame
ComRxEGRMsFlw1
524107 9
1678 Timeout error of
CAN-Receive-Frame
ComRxEGRMsFlw2
524108 9
1669 Timeout error of
CAN-Transmit-Frame
ComEGRTVActr
524109 9
1679 Timeout error of
CAN-Receive-Frame
ComRxEGRTVActr
524110 9
1670 Timeout error of
CAN-Transmit-Frame
ComETVActr
524111 9
1680 Timeout error of
CAN-Receive-Frame
ComRxETVActr
524112 9
1671 Timeout ComITVActr
524113 9
1681 Timeout error of
CAN-Receive-Frame
ComRxITVActr
142
SPN
FMI
KWP Description
524114 9
1659 Timeout error of
CAN-Transmit-Frame A1DOC
524115 9
1660 Timeout error of
CAN-Transmit-Frame AT1S
524116 9
1661 Timeout error of
CAN-Transmit-Frame SCR2
524117 9
1662 Timeout error of
CAN-Transmit-Frame SCR3
524118 9
1672 Timeout error of
CAN-Receive-Frame
ComRxCM1
524119 9
1673 Timeout error of
CAN-Receive-Frame
ComRxCustSCR3
524120 9
1682 Timeout error of
CAN-Receive-Frame
ComRxSCRHtDiag
524121 9
1683 Timeout error of
CAN-Receive-Frame
ComRxTrbChActr
524122 9
1684 Timeout error of
CAN-Receive-Frame
ComRxUQSens
524123 9
1685 Timeout error of
CAN-Receive-Frame
ComSCRHtCtl
524124 9
1686 Timeout error of
CAN-Receive-Frame
ComTxAT1IMG
524125 9
1687 Timeout error of
CAN-Receive-Frame
ComTxTrbChActr
Part No. 1268556
September 2016
Service and Repair Manual
Perkins 404F-22 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
723
3
Engine Speed Sensor #2: Voltage
Above Normal
SPN
FMI
Description
723
4
29
3
Accelerator Pedal Position 2: Voltage
Above Normal
Engine Speed Sensor #2: Voltage
Below Normal
723
8
29
4
Accelerator Pedal Position 2: Voltage
Below Normal
Engine Speed Sensor#2: Abnormal
Frequency, Pulse Width or Period"
723
10
91
3
Accelerator Pedal Position 1: Voltage
Above Normal
Engine Speed Sensor #2: Abnormal
Rate of Change
733
3
91
4
Accelerator Pedal Position 1: Voltage
Below Normal
Engine Rack Position Sensor: Voltage
Above Normal
733
4
100
1
Engine Oil Pressure :Low- most
severe (3)
Engine Rack Position Sensor: Voltage
Below Normal
1485
7
108
3
Barometric Pressure : Voltage Above
Normal
ECU Main Relay : Not Responding
Property
2840
11
ECU Instance: Other Failure Mode
108
4
Barometric Pressure : Voltage Below
Normal
2840
12
ECU Instance: Failure
2840
13
ECU Instance: Out of Calibration
2970
3
Engine Coolant Temperature : Voltage
Below Normal
Accelerator Pedal 2 Low Idle Switch:
Voltage Above Normal
2970
4
Engine Coolant Temperature : High
-least severe (1)
Accelerator Pedal 2 Low Idle Switch:
Voltage Below Normal
3241
1
Battery Potential/ Power Input 1 :
High- most severe (3)
Exhaust Gas Temperature 1: Lowmost severe (3)
3241
3
Battery Potential/ Power Input 1:
Voltage Above Normal
Exhaust Gas Temperature 1: Voltage
Above Normal
241
4
Battery Potential/ Power Input 1:
Voltage Below Normal
Exhaust Gas Temperature 1: Voltage
Below Normal
3241
15
Engine Air Inlet Temperature: Voltage
Above Normal
Exhaust Gas Temperature 1: Highleast severe (1)
3241
16
Engine Air Inlet Temperature: Voltage
Below Normal
Exhaust Gas Temperature 1: Highmoderate severity (2)
3242
1
Particulate Trap Intake Gas Temp:
Low- most severe(3)"
3242
3
Particulate Trap Intake Gas Temp:
Voltage Above Normal"
3242
4
Particulate Trap Intake Gas Temp:
Voltage Below Normal"
3242
15
Particulate Trap Intake Gas Temp:
High - least severe(1)"
3242
16
Particulate Trap Intake Gas Temp:
High-moderate severity (2)
110
110
110
168
168
168
172
172
3
4
15
0
3
4
3
4
Engine Coolant Temperature : Voltage
Above Normal
190
0
Engine Speed : High- most severe (3)
190
8
Engine Speed : Abnormal Frequency,
Pulse Width or Period
558
3
Accelerator Pedal1 Low Idle Switch:
Voltage Above Normal
558
4
Accelerator Pedal1 Low Idle Switch:
Voltage Below Normal
638
6
Engine Fuel Rack Actuator: Current
Above Normal
639
14
J1939 Network#1: Special Instruction
Part No. 1268556
143
Service and Repair Manual
September 2016
Perkins 404F-22 Engine Fault Codes
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
4201
4
Engine Speed Sensor #1: Voltage
Below Normal
SPN
FMI
Description
3251
3
Particulate Trap Differential Pressure:
Voltage Above Normal
4201
8
Engine Speed Sensor #1: Abnormal
Frequency, Pulse \Nidth, or Period
3251
4
Particulate Trap Differential Pressure:
Voltage Below Normal
4201
10
Engine Speed Sensor #1: Abnormal
Rate of Change
3473
7
Aftertreatmert #1 Failed to Ignite: Not
Responding Properly
4765
1
3473
11
Aftertreatmert #1 Failed to Ignite :
Other Failure Mode
Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
Low-most severe (3)
4765
3
3484
0
Aftertreatmert #1 Ignition : High-most
severe (3)
Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
Voltage Above Normal
3484
3
Aftertreatmert #1 Ignition : Voltage
Above Normal
4765
4
3484
4
Aftertreatmert #1 Ignition : Voltage
Below Normal
Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
Voltage Below Normal
4765
15
3556
6
Aftertreatmert 1 Hydrocarbon Doser 1:
Current Above Normal
Aftertreatmert #1Diesel Oxidation
Catalyst Intake Gas Temperature:
High-least severe (1)
3610
3
Diesel Particulate Filter Outlet
Pressure or 1: Voltage Above Normal"
4765
16
Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
High-moderate severity (2)
3610
4
DieselParticulate Filter Outlet
Pressure Sensor 1: Voltage Below
Normal
5487
3
Aftertreatmert 1 Burner Unit
Combustion Chamber Temperature:
Voltage Above Normal
3713
7
DPF Active Regeneration Inhibited
Due to System Timeout: Not
Responding Properly
5487
4
Aftertreatmert 1 Burner Unit
Combustion Chamber Temperature:
Voltage Below Normal
3713
31
DPF Active Regeneration Inhibited
Due to System Timeout
6581
6
Aftertreatmert 1 Hydrocarbon Doser
2 : Current Above Normal
3719
0
Particulate Trap #1 Soot Load
Percent: High- most severe (3)
3719
16
Particulate Trap #1 Soot Load
Percent: High-moderate severity (2)
4016
6
High Current Auxiliary Power Relay 1:
Current Above Normal
4201
3
Engine Speed Sensor #1: Voltage
Above Normal
144
Part No. 1268556
September 2016
Service and Repair Manual
Continental TME27 Engine Fault Codes
How to R etrieve Conti nental Engine F ault C odes
How to Retrieve Continental
Engine Fault Codes
The ECM constantly monitors the engine by the use
of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of set
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and
will turn on the Check Engine Light.
Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. Refer
to How to Clear Engine Fault Codes from the ECM.
How to Cl ear Engine Fault Codes fr om the ECM
How to Clear Engine Fault Codes
from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1
Open the engine side turntable cover and
locate the battery.
2
Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
Note: Perform this procedure with the key switch in
the off position.
1
Open the ground controls side cover and
locate the run/test toggle switch on the side of
the ground control box.
2
Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3
Quickly activate and release the start toggle
switch/button. Do not start the engine.
4
Move and hold the run/test toggle switch to the
test position.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3
Connect the negative battery cable to the
battery.
Result: The check engine light should turn on.
The check engine light should begin to blink.
5
Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 1654 three
times. After the fault codes, the check engine light
will blink a code 1654 three times again indicating
the end of the stored codes.
Note: If any fault codes are present, the ECM will
blink a three or four digit code three times for each
code stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, blink the third digit, then pause and possibly
a fourth digit. For example: the check engine light
blinks 5 consecutive times, blinks 3 times and then
1 time. That would indicate code 531.
Part No. 1268556
145
Service and Repair Manual
September 2016
Continental TME27 Engine Fault Codes
Continental TME27 Engine F ault Codes
System
Code
Fault Name
MAP
108
MAP Pressure High
Y Y
MAP pressure > 16 psi and TPS < 10%
and RPM > 1800 To Unlatch, MAP
pressure must be < 10 psi
107
MAP Voltage Low
Y Y
MAP voltage < 0.05 vdc and TPS > 2%
and RPM < 7000 To Unlatch, MAP
voltage must be > 0.5 vdc
118
ECT Voltage High
Y
ECT voltage > 4.95 vdc
117
ECT Voltage Low
Y
ECT voltage < 0.05 vdc
116
ECT higher than expected 1
Y Y Y
ECT > 210° F and RPM > 600
217
ECT higher than expected 2
113
IAT Voltage High
Y
IAT voltage > 4.95 vdc
112
IAT Voltage Low
Y
IAT voltage < 0.05 vdc
111
IAT higher than expected 1
Y
127
IAT higher than expected 2
2229
BP Pressure High
Y Y
BP pressure > 16 psi
129
BP Pressure Low
Y Y
BP pressure < 8.3 psi
Y Y
Voltage > 18 vdc
Voltage Low
Y Y
Voltage < 9.5 vdc and RPM > 1500
5V External 643
5VE1 High Voltage
Y
5VE1 > 5.4 vdc
642
5VE1 Low Voltage
Y
5VE1 < 4.6 vdc
123
TPS1 High Voltage
Y
TPS1 voltage > 4.8 vdc
122
TPS1 Low Voltage
Y
TPS1 voltage < 0.2 vdc
223
TPS2 High Voltage
Y
TPS2 voltage > 4.8 vdc
222
TPS2 Low Voltage
Y
TPS2 voltage < 0.2 vdc
221
TPS1 > than TPS2
Y
(TPS1 percent - TPS2 percent) > 20%
121
TPS1 < than TPS2
Y
(TPS1 percent - TPS2 percent) < -20%
2112
Unable to reach > TPS
Y
(target TPS - actual TPS) > 20%
2111
Unable to reach < TPS
Y
(target TPS - actual TPS) < -20%
2135
TPS1/2 simultaneous voltages Y
out of range
ECT/ CHT
IAT
BP
Battery
Voltage
563
562
TPS
1 = Shutdown
146
1
Y
ECT > 230° F and RPM > 600
Y
Y
Voltage High
2 = AL disable
2 3 4 5 6 Fault Conditions
3 = AL disable key-cycle
IAT > 200° F and RPM > 1000
IAT > 210° F and RPM > 1000
Uses same parameters as individual
TPS1/2 voltage fault detection above
4 = Power derate 1
5 = Power derate 2
6 = Low rev limit
Part No. 1268556
September 2016
Service and Repair Manual
Continental TME27 Engine Fault Codes
System
Code
Fault Name
FPP
2122
FPP1 High Voltage
Y FPP1 voltage > 4.8 vdc
2123
FPP1 Low Voltage
Y FPP1 voltage < 0.2 vdc
219
Max Govern Speed Override
RPM > 3400
1111
Rev Fuel Limit
RPM > 3600
1112
Spark Rev Limit
Y
RPM > 3800
Oil Pressure 524
Oil Pressure Low
Y
Oil pressure pulled-up input with a
threshold voltage of 2.5 vdc and RPM >
500 and run-time > 30 s
Adaptive
Learn
171
AL High Gasoline Bank 1
AL_BM > 30% and RPM between
0-9999 and MAP between 0-99 psi
172
AL Low Gasoline Bank 1
AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
1161
AL High LPG
AL_BM > 30% and RPM between
0-9999 and MAP between 0-99 psi
1162
AL Low LPG
AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
1155
CL High Gasoline Bank 1
CL_BM > 40% and RPM between
0-9999 and MAP between 0-99 psi
1156
CL Low Gasoline Bank 1
CL_BM <-40% and RPM between
0-9999 and MAP between 0-99 psi
1151
CL High LPG
CL_BM > 35% and RPM between
0-9999 and MAP between 0-99 psi
1152
CL Low LPG
CL_BM < -35% and RPM between
0-9999 and MAP between 0-99 psi
420
Gasoline Cat Monitor
Y
Y
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
1165
LPG Cat Monitor
Y
Y
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
Engine
Speed
Closed
Loop
Catalyst
Monitor
1 = Shutdown
2 = AL disable
Part No. 1268556
1
3 = AL disable key-cycle
2
3 4 5 6 Fault Conditions
4 = Power derate 1
5 = Power derate 2
6 = Low rev limit
147
Service and Repair Manual
September 2016
Continental TME27 Engine Fault Codes
System
Code
Fault Name
FPP
2122
FPP1 High Voltage
Y FPP1 voltage > 4.8 vdc
2123
FPP1 Low Voltage
Y FPP1 voltage < 0.2 vdc
219
Max Govern Speed Override
RPM > 3400
1111
Rev Fuel Limit
RPM > 3600
1112
Spark Rev Limit
Y
RPM > 3800
Oil Pressure 524
Oil Pressure Low
Y
Oil pressure pulled-up input with a
threshold voltage of 2.5 vdc and RPM >
500 and run-time > 30 s
Adaptive
Learn
171
AL High Gasoline Bank 1
AL_BM > 30% and RPM between
0-9999 and MAP between 0-99 psi
172
AL Low Gasoline Bank 1
AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
1161
AL High LPG
AL_BM > 30% and RPM between
0-9999 and MAP between 0-99 psi
1162
AL Low LPG
AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
1155
CL High Gasoline Bank 1
CL_BM > 40% and RPM between
0-9999 and MAP between 0-99 psi
1156
CL Low Gasoline Bank 1
CL_BM <-40% and RPM between
0-9999 and MAP between 0-99 psi
1151
CL High LPG
CL_BM > 35% and RPM between
0-9999 and MAP between 0-99 psi
1152
CL Low LPG
CL_BM < -35% and RPM between
0-9999 and MAP between 0-99 psi
420
Gasoline Cat Monitor
Y
Y
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
1165
LPG Cat Monitor
Y
Y
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
Engine
Speed
Closed
Loop
Catalyst
Monitor
1 = Shutdown
148
2 = AL disable
1
3 = AL disable key-cycle
2
3 4 5 6 Fault Conditions
4 = Power derate 1
5 = Power derate 2
6 = Low rev limit
Part No. 1268556
September 2016
Service and Repair Manual
Continental TME27 Engine Fault Codes
System
Code Fault Name
EGO
Sensors
134
EGO Open/Lazy Pre-cat 1
Y Y
EGO cold persistently > 120 seconds
154
EGO Open/Lazy Post-cat 1
Y Y
EGO cold persistently > 120 seconds
261
Injector Loop Open or
n Y Y Y
Low-Side Short to Ground
Injector off-state low-side < 4 vdc and battery
voltage > 9 vdc
262
Injector Coil Shorted
Injector on-state low-side > 4 vdc and battery
voltage < 16 vdc
Injectors
Power Relay 686
Control Coil
Tach
Output
EPR
Diagnostics
LPG
1 2 3 4 5 6 Fault Conditions
Y Y Y
Relay Control Ground
Short
685
Relay Coil Short
687
Relay Coil Short to Pwr
2618
Tach Output Ground Short
Does not turn on MIL
2619
Tach Output Short to Pwr
Does not turn on MIL
1171
EPR Delivery Pressure >
than expected
Y
Y
MJ actual-commanded press > 4 in. H20
1172
EPR Delivery Pressure <
than expected
Y
Y
MJ actual-commanded press < 4 in. H20
1173
EPR Comm Lost
Y
Y
No MJ packets received within 500 ms
1174
EPR Voltage Supply High
Y
Y
1175
EPR Voltage Supply Low
Y
Y
1176
EPR Internal Actuator
Y
Y
1177
EPR Internal Circuitry fault n Y
detection
Y
1178
EPR Internal Comm fault
detection
Y
fault detection
1 = Shutdown
2 = AL disable
Part No. 1268556
n Y
3 = AL disable key-cycle
4 = Power derate 1
5 = Power derate 2
6 = Low rev limit
149
Service and Repair Manual
September 2016
Continental TME27 Engine Fault Codes
System
Code Fault Name
Cam Crank 342
Sensors
337
1 = Shutdown
150
Y Y
6
Fault Conditions
No cam pulse in 4 cycles and RPM > 1000
Crank Loss
Cam pulses without crank activity > 6 cam
pulses
341
Cam Sync Noise
Y Y
Number of invalid cam re-syncs = 1 within a time
window of <= 700 ms
336
Crank Sync Noise
Y Y
Number of invalid crank re-syncs = 1 within a
time window of <= 800 ms
16
Never Crank Synced at
Start
Internal
606
Process or
Diagnostics 1612
J1939
Network
Cam Loss
1 2 3 4 5
Cranking revs without sync < 4 revs and RPM >
90 rpm
COP Failure
Y
Y
RTI 1 Loss
Y
Y
1613
RTI 2 Loss
Y
Y
1614
RTI 3 Loss
Y
Y
1615
A/D Loss
Y
Y
1616
Invalid Interrupt
Y
Y
601
Flash Checksum Invalid
Y
Y
604
RAM Failure
Y
Y
1625
Shutdown Request
Number of shutdown requests >= 1
1626
CAN Tx Failure
TX error counter > 100
1627
CAN Rx Failure
Rx error counter > 100
1628
CAN Address Conflict
Failure
Address conflict counter > 5
2 = AL disable
3 = AL disable key-cycle
4 = Power derate 1
5 = Power derate 2
6 = Low rev limit
Part No. 1268556
September 2016
Service and Repair Manual
GM 3.0L Engine Fault Codes
GM Fault Code Chart
Description
DTC 11: Intake cam / distributor position error
DTC 16: Crank and/or cam no sync during start
DTC 24: Exhaust cam position error
DTC Set 2
SPN-2/FMI-2
Description
520800 / 7 DTC 221: TPS1-2 higher than expected
636 / 8
DTC 222: TPS2 voltage low
520801 / 7 DTC 223: TPS2 voltage high
DTC Set 2
SPN-2/FMI-2
653/6
520251 / 4
520251 / 3
DTC 87 Fuel pressure lower than expected
94 / 1
DTC 234: Boost control overboost failure
1692 / 0
DTC 88 Fuel pressure higher than expected
94 / 0
DTC 236: TIP active
1692 / 2
DTC 91: FP low voltage
94 / 4
DTC 237: TIP low voltage
1127 / 4
DTC 92: FP high voltage
94 / 3
DTC 238: TIP high voltage
1127 / 3
DTC 107: MAP voltage low
106 / 4
DTC 261: Injector 1 open or short to ground
651 / 5
DTC 108: MAP pressure high
106 / 16
DTC 262: Injector 1 coil shorted
651 / 6
DTC 111: IAT higher than expected stage 1
105 / 15
DTC 264: Injector 2 open or short to ground
652 / 5
DTC 112: IAT voltage low
105 / 4
DTC 265: Injector 2 coil shorted
652 / 6
DTC 113: IAT voltage high
105 / 3
DTC 267: Injector 3 open or short to ground
653 / 5
DTC 116: ECT higher than expected stage 1
110 / 15
DTC 268: Injector 3 coil shorted
653/6
DTC 117: ECT voltage low
110 / 4
DTC 270: Injector 4 open or short to ground
654 / 5
DTC 118: ECT voltage high
110 / 3
DTC 271: Injector 4 coil shorted
654 / 6
DTC 121: TPS1-2 lower than expected
51 / 1
DTC 273: Injector 5 open or short to ground
655 / 5
DTC 122: TPS1 voltage low
51 / 4
DTC 274: Injector 5 coil shorted
655 / 6
DTC 123: TPS1 voltage high
51 / 3
DTC 276: Injector 6 open or short to ground
656 / 5
DTC 127: IAT higher than expected stage 2
105 / 0
DTC 277: Injector 6 coil shorted
656 / 6
DTC 129: BP pressure low
108 / 1
DTC 279: Injector 7 open or short to ground
657 / 5
724 / 10
DTC 134: EGO1 open / lazy
DTC 280: Injector 7 coil shorted
657 / 6
DTC 140: EGO3 open / lazy
520209 / 10 DTC 282: Injector 8 open or short to ground
658 / 5
DTC 154: EGO2 open / lazy
520208 / 10 DTC 283: Injector 8 coil shorted
658 / 6
DTC 160: EGO4 open / lazy
520210 / 10 DTC 285: Injector 9 open or short to ground
659 / 5
DTC 171: Adaptive-learn gasoline bank1 high
520200 / 0 DTC 308: Cylinder 8 emissions/catalyst damaging misfire 1330 / 31
DTC 172: Adaptive-learn gasoline bank1 low
520200 / 1 DTC 326: Knock1 excessive or erratic signal
731 / 2
DTC 174: Adaptive-learn gasoline bank2 high
520201 / 0 DTC 327: Knock1 sensor open or not present
731 / 4
DTC 175: Adaptive-learn gasoline bank2 low
520201 / 1 DTC 331: Knock2 excessive or erratic signal
520241 / 2
DTC 182: FT low voltage
174 / 4
DTC 332: Knock2 sensor open or not present
DTC 183: FT high voltage
174 / 3
DTC 336: CRANK input signal noise
520241 / 4
636 / 2
DTC 187: Gaseous fuel temp sender low voltage 520240 / 4 DTC 337: Crank signal loss
636 / 4
DTC 188: Gaseous fuel temp sendr high voltage 520240 / 3 DTC 341: CAM input signal noise
723 / 2
DTC 217: ECT higher than expected stage 2
723 / 4
DTC 219: RPM higher than max allowed govern
speed
Part No. 1268556
110 / 0
515 / 15
DTC 342: Loss of CAM input signal
DTC 359: Fuel run-out longer than expected
1239 / 7
151
Service and Repair Manual
September 2016
GM 3.0L Engine Fault Codes
GM Fault Code Chart
Description
DTC Set 2
SPN-2 / FMI-2
DTC Set 2
SPN-2 / FMI-2
Description
DTC 420: Catalyst inactive on gasoline (Bank 1) 520211 / 10 DTC 1111: RPM above fuel rev limit level
515 / 16
DTC 430: Catalyst inactive on gasoline (Bank 2) 520212 / 10 DTC 1112: RPM above spark rev limit level
515 / 0
DTC 502: Roadspeed input loss of signal
84 / 1
DTC 1121: FPP1/2 simultaneous voltages
out-of-range
91 / 31
DTC 508: IAC ground short
520252 / 6
DTC 1122: FPP1/2 do not match each other or IVS
DTC 509: IAC coil open/short
520252 / 5
DTC 1131: WGP voltage high
100 / 18
DTC 1132: WGP voltage low
DTC 520: Oil pressure sndr low prssure stage 1
520250 / 31
1192 / 3
1192 / 4
DTC 521: Oil pressure sender high pressure
100/ 0
DTC 1151: Closed-loop LPG high
520206 / 0
DTC 522: Oil pressure sender low voltage
651 / 5
DTC 1152: Closed-loop LPG low
520206 / 1
DTC 523: Oil pressure sender high voltage
100 / 3
DTC 1153: Closed-loop NG high
520207 / 0
DTC 524: Oil pressure low
100 / 1
DTC 1154: Closed-loop NG low
520207 / 1
DTC 562: Vbat voltage low
168 / 17
DTC 1155: Closed-loop gasoline bank1 high
520204 / 0
DTC 563: Vbat voltage high
168 / 15
DTC 1156: Closed-loop gasoline bank1 low
520204 /
DTC 601: Microprocessor failure - FLASH
628 / 13
DTC 1157: Closed-loop gasoline bank2 high
520205 / 0
DTC 604: Microprocessor failure - RAM
630 / 12
DTC 1158: Closed-loop gasoline bank2 low
520205 / 1
DTC 606: Microprocessor failure - COP
629 / 31
DTC 1161: Adaptive-learn LPG high
520202 / 0
DTC 615: Start relay coil open
1321 / 5
DTC 1162: Adaptive-learn LPG low
520202 / 1
DTC 616: Start relay ground short
1321 / 4
DTC 1163: Adaptive-learn NG high
520203 / 0
DTC 617: Start relay coil short to power
1321 / 3
DTC 1164: Adaptive-learn NG low
520203 / 1
DTC 627: Fuel pump relay coil open
1348 / 5
DTC 1165: Catalyst inactive on LPG
520213 / 10
DTC 628: Fuel-pump high-side open or short to
ground
1347 / 5
DTC 1166: Catalyst inactive on NG
520214 / 0
1348 / 4
DTC 1171: MegaJector delivery pressure higher than
expected
520260 / 0
1347 / 6
DTC 1172: MegaJector delivery pressure lower than
expected
520260 / 1
DTC 629: Fuel pump relay coil short to power
1348 / 3
DTC 1173: MegaJector comm lost
520260 / 31
DTC 642: Sensor supply voltage 1 low
1079 / 4
DTC 1174: MegaJector voltage supply high
520260 / 3
DTC 643: Sensor supply voltage 1 high
1079 / 3
DTC 1175: MegaJector voltage supply low
520260 / 4
1213 / 5
DTC 1176: MegaJector internal actuator fault
detection
520260 / 12
1080 / 4
DTC 1177: MegaJector internal circuitry fault
detection
520260 / 12
DTC 653: Sensor supply voltage 2 high
1080 / 3
DTC 1178: MegaJector internal comm fault detection 520260 / 12
DTC 685: Power relay coil open
1485 / 5
DTC 1182: Fuel impurity level high
520401 / 0
DTC 686: Power relay ground short
1485 / 4
DTC 1183: MegaJector autozero / lockoff failure
520803 / 31
DTC 628: Fuel pump relay control ground short
DTC 629: Fuel-pump high-side short to power
DTC 650: MIL open
DTC 652: Sensor supply voltage 2 low
DTC 687: Power relay coil short to power
1485 / 3
DTC 1311: Cylinder 1 misfire detected
1323 / 11
520226 / 3
DTC 1312: Cylinder 2 misfire detected
1324 / 11
DTC 919: Shift unable to reach desired gear
520226 / 7
DTC 1313: Cylinder 3 misfire detected
1325 / 11
DTC 920: Shift actuator or drive circuit failed
520226 / 31 DTC 1314: Cylinder 4 misfire detected
1326 / 11
DTC 916: Shift actuator feedback out-of-range
152
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GM 3.0L Engine Fault Codes
GM Fault Code Chart
Description
DTC Set 2
SPN-2 /
FMI-2
Description
DTC Set 2
SPN-2 /
FMI-2
DTC 1315: Cylinder 5 misfire detected
1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage
520220 / 3
DTC 1316: Cylinder 6 misfire detected
1328 / 11 DTC 1544: AUX analog Pull-Up/Down 2 low voltage
520220 / 4
DTC 1317: Cylinder 7 misfire detected
1329 / 11 DTC 1545: AUX analog Pull-Up/Down 3 high voltage
520221 / 3
DTC 1318: Cylinder 8 misfire detected
1330 / 11 DTC 1546: AUX analog Pull-Up/Down 3 low voltage
520221 / 4
DTC 1411: EMWT1 voltage high
441 / 3
DTC 1547: AUX analog Pull-Up/Down 4 high voltage
DTC 1412: EMWT2 voltage high
442 / 3
DTC 1548: AUX analog Pull-Up/Down 4 low voltage
DTC 1413: EMWT1 voltage low
441 / 4
DTC 1551: AUX digital 1 high voltage
520222 / 3
DTC 1414: EMWT2 voltage low
442 / 4
DTC 1552: AUX digital 1 low voltage
520222 / 4
DTC 1415: EMWT1 higher than expected stage 1
441 / 15
DTC 1553: AUX digital 2 high voltage
520223 / 3
DTC 1416: EMWT2 higher than expected stage 1
442 / 15
DTC 1554: AUX digital 2 low voltage
520223 / 4
DTC 1417: EMWT1 higher than expected stage 2
441 / 0
DTC 1555: AUX digital 3 high voltage
520224 / 3
DTC 1418: EMWT2 higher than expected stage 2
442 / 0
DTC 1555: Water Intrusion Detection
520224 / 3
DTC 1419: ERWT1 voltage high
443 / 3
DTC 1556: AUX digital 3 low voltage
520224 / 4
DTC 1420: ERWT2 voltage high
444 / 3
DTC 1561: AUX analog Pull-Down 2 high voltage
0/3
DTC 1421: ERWT1 voltage low
443 / 4
DTC 1561: AUX analog Pull-Down 3 high voltage
0/4
DTC 1422: ERWT2 voltage low
444 / 4
DTC 1561: AUX analog Pull-Down 2 low voltage
DTC 1423: ERWT1 higher than expected stage 1
443 / 15
DTC 1611: Sensor supply voltage 1 and 2 out-of-range
1079 / 31
DTC 1424: ERWT2 higher than expected stage 1
444 / 15
DTC 1612: Microprocessor failure - RTI 1
629 / 31
DTC 1425: ERWT1 higher than expected stage 2
443 / 0
DTC 1613: Microprocessor failure - RTI 2
629 / 31
444 / 0
DTC 1614: Microprocessor failure - RTI 3
629 / 31
DTC 1426: ERWT2 higher than expected stage 2
713 / 3
713 / 4
0/4
DTC 1511: AUX analog Pull-Up 1 high voltage
520216 / 3 DTC 1615: Microprocessor failure - A/D
629 / 31
DTC 1511: AUX analog Pull-Up 1 high voltage
520216 / 3 DTC 1616: Microprocessor failure - Interrupt
629 / 31
DTC 1512: AUX analog Pull-Up 1 low voltage
520216 / 4 DTC 1621: RS-485 Rx inactive
0 / 31
DTC 1513: AUX analog Pull-Up 2 high voltage
520217 / 3 DTC 1622: RS-485 Rx noise
0 / 31
DTC 1514: AUX analog Pull-Up 2 low voltage
520217 / 4 DTC 1623: RS-485 Rx bad packet format
0 / 31
DTC 1515: AUX analog Pull-Down 1 high voltage 520215 / 3 DTC 1624: RS-485 remote shutdown request
0 / 31
DTC 1516: AUX analog Pull-Down 1 low voltagee 520215 / 4 DTC 1625: J1939 shutdown request
1384 / 31
DTC 1517: AUX analog Pull-Up 3 high voltage
520218 / 3 DTC 1626: CAN-J1939 Tx fault
639 / 12
DTC 1518: AUX analog Pull-Up 3 low voltage
520218 / 4 DTC 1627: CAN-J1939 Rx fault
639 / 12
DTC 1521: CHT higher than expected stage 1
110 / 16
DTC 1628: J1939 CAN address / engine-number conflict
639 /13
DTC 1522: CHT higher than expected stage 2
110 / 0
DTC 1629: J1939 TSC1 message receipt loss
639 / 9
DTC 1531: Gov1/2/3 interlock failure
520270 / 31 DTC 1630: J1939 ETC message receipt loss
DTC 1541: AUX analog Pull-Up/Down 1 high
voltage
520219 / 3
DTC 1542: AUX analog Pull-Up/Down 1 low
voltage
520219 / 4
Part No. 1268556
DTC 1632: PWM1-Gauge1 short to power
DTC 1633: PWM2-Gauge2 open / ground short
91 / 2
697 / 6
698 / 5
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GM 3.0L Engine Fault Codes
GM Fault Code Chart
Description
DTC Set 2
SPN-2 / FMI-2
DTC Set 2
SPN-2 / FMI-2
Description
DTC 1634: PWM2-Gauge2 short to power
698 / 6
DTC 2126: FPP1-2 higher than expected
91 / 16
DTC 1635: PWM3-Gauge3 open / ground short
699 / 6
DTC 2127: FPP2 voltage low
29 / 4
DTC 1636: PWM3-Gauge3 short to power
700 / 5
DTC 2128: FPP2 voltage high
29 / 3
DTC 1637: PWM4 open / ground short
700 / 6
DTC 2130: IVS stuck at-idle, FPP1/2 match
558 / 5
DTC 1638: PWM4 short to power
520230 / 5
DTC 2131: IVS stuck off-idle, FPP1/2 match
558 / 6
DTC 1639: PWM5 open / ground short
520230 / 5
DTC 2135: TPS1/2 simultaneous voltages out-of-range
51 / 31
DTC 1640: PWM5 short to power
520230 / 6
DTC 2139: FPP1 lower than IVS
91 / 1
DTC 1641: Buzzer control ground short
920 / 4
DTC 2140: FPP2 lower than IVS
29 / 1
DTC 1642: Buzzer open
920 / 5
DTC 2229: BP pressure high
108 / 0
DTC 1643: Buzzer control short to power
920 / 3
DTC 2300: Spark coil 1 primary open or short to ground
1268 / 5
DTC 1644: MIL control ground short
1213 / 4
DTC 2301: Spark coil 1 primary shorted
1268 / 6
DTC 1645: MIL control short to power
1213 / 3
DTC 2303: Spark coil 2 primary open or short to ground
1269 / 5
DTC 2304: Spark coil 2 primary shorted
DTC 1651: J1939 ETC message receipt loss
while in-gear
91 / 9
DTC 1661: PWM6 open / ground short
925 / 5
DTC 2306: Spark coil 3 primary open or short to ground
1270 / 5
DTC 1662: PWM6 short to power
925 / 3
DTC 2307: Spark coil 3 primary shorted
1270 / 6
DTC 1663: PWM7 open / ground short
926 / 5
DTC 2309: Spark coil 4 primary open or short to ground
1271 / 5
DTC 1664: PWM7 short to power
926 / 3
DTC 2310: Spark coil 4 primary shorted
1271 / 6
DTC 1665: PWM8 open / ground short
2646 / 5
DTC 2312: Spark coil 5 primary open or short to ground
1272 / 5
DTC 1666: PWM8 short to power
2646 / 3
DTC 2313: Spark coil 5 primary shorted
1272 / 6
DTC 1669: PWM9 open / ground short
2647 / 5
DTC 2315: Spark coil 6 primary open or short to ground
1273 / 5
DTC 1670: PWM9 short to power
2647 / 3
DTC 2316: Spark coil 6 primary shorted
1273 / 6
1269 / 6
DTC 2111: Unable to reach lower TPS
51 / 7
DTC 2318: Spark coil 7 primary open or short to ground
1274 / 5
DTC 2112: Unable to reach higher TPS
51 / 7
DTC 2319: Spark coil 7 primary shorted
1274 / 6
DTC 2115: FPP1 higher than IVS
91 / 0
DTC 2321: Spark coil 8 primary open or short to ground
1275 / 5
DTC 2116: FPP2 higher than IVS
29 / 0
DTC 2322: Spark coil 8 primary shorted
1275 / 6
DTC 2120: FPP1 invalid voltage and
FPP2 disagrees with IVS
DTC 2121: FPP1-2 lower than expected
DTC 2122: FPP1 voltage high
DTC 2123: FPP1 voltage low
DTC 2125: FPP2 invalid voltage and
FPP1 disagrees with IVS
154
520250 / 31
DTC 2324: Spark coil 9 primary open or short to ground
1276 / 5
91 / 18
DTC 2325: Spark coil 9 primary shorted
1276 / 6
91 / 3
DTC 2327: Spark coil 10 primary open or short to
ground
1277 / 5
91 / 4
DTC 2328: Spark coil 10 primary shorted
1277 / 6
520250 / 31
DTC 2428: EGT temperature high
173 / 0
Part No. 1268556
September 2016
Service and Repair Manual
GM 3.0L Engine Fault Codes
GM Fault Code Chart
Description
DTC 2618: Tach output ground short
DTC Set 2
SPN-2 / FMI-2
Description
DTC Set 2
SPN-2 / FMI-2
645 / 4
DTC 8909: UEGO pump voltage shorted low
3218 / 3
DTC 2619: Tach output short to power
645 / 3
DTC 8910: UEGO sense cell voltage high
3218 / 3
DTC 8901: UEGO microprocessor internal fault
3221 / 1
DTC 8911: UEGO sense cell voltage low
3218 / 4
DTC 8902: UEGO heater supply high voltage
3222 / 3
DTC 8912: UEGO pump voltage at high drive limi
3217 / 3
DTC 8903: UEGO heater supply low voltage
3222 / 4
DTC 8913: UEGO pump voltage at low drive limit
3217 / 3
DTC 8904: UEGO cal resistor voltage high
3221 / 3
DTC 8914: UEGO sense cell slow to warm up
3225 / 4
DTC 8905: UEGO cal resistor voltage low
3221 / 4
DTC 8915: UEGO pump cell slow to warm up
3222 / 4
DTC 8906: UEGO return voltage shorted high
3056 / 3
DTC 8916: UEGO sense cell impedance high
3225 / 10
DTC 8907: UEGO return voltage shorted low
3056 / 4
DTC 8917: UEGO pump cell impedance high
3225 / 0
DTC 8908: UEGO pump voltage shorted high
3218 / 3
DTC 8918: UEGO pump cell impedance low
3225 / 1
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Schematics
Section 5
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey:
 Troubleshooting and repair procedures shall be
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine
 Immediately tag and remove from service a
damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
 Read, understand and obey the safety rules
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and test
equipment are available and ready for use.
156
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Wire Circuit Legend
Circuit numbering
1
2
Circuit numbers consist of three parts: the
circuit prefix, circuit number and circuit suffix.
The circuit prefix indicates the type of circuit.
The circuit number describes the function of
the circuit. The circuit suffix provides an
abbreviation for the number or may be used to
further define the function of this portion of the
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw.
The circuit number may be used more than
once in a circuit.
For Example:
Circuit prefix
C
Control
D
Data
E
Engine
G
Gauges
N
Neutral
P
Power
R
Relay Output
S
Safety
V
Valve
C 74 PL – This is the circuit for the lockout valve #1.
C stands for control, 74 is the number of the circuit
for the primary #1 lock out valve. PL stands for
Primary Lockout.
S 62 BST – This is the circuit that communicates to
the onboard computers of the machine that the
boom is fully stowed. S stands for safety, 62 is the
number of the circuit for boom stowed and BST
stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit
number for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the
wire that feeds the relay coil for the work lamp. All
other numbers remain the same.
V61AXR – V stands for valve power. Number
61 stands for axle retracted circuit; AXR stands for
Axle retracted.
R46HRN – R stands for Relay output, supplying
power to the horn (HRN). Number 46 is the circuit
number for the horn.
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Wire Circuit Legend
Suffix
Definition
Suffix
Definition
ABV
Auxiliary Boom Valve
ESP
Engine Speed Select
AF
Alternator Field
FAP
Axle Front Position
AFV
Auxiliary Forward Valve
FB
Flashing Beacon
AH
Auxiliary Hydraulic Pump
FE
Function Enable
ANG
Angle
FL
Fuel Select (gas/LP)
APV
Auxiliary Platform Valve
FLR
Filter Restricted
ARV
Auxiliary Reverse Valve
FLT
Filter Switch
ASV
Auxiliary Steer/Drive Valve
FP
Fuel Pump
AXE
Axle Extend Valve
FS
Float Switch
AXO
Axle Oscillate
FSL
Fuel Solenoid
AXR
Axle Retract Valve
FTS
Foot switch Signal
BAT
Battery
FWD
Forward
BEX
Boom Extended
GEN
AC Generator
BRK
Brake
GND
Ground
BST
Boom Stowed
HG
Hydraulic Generator
BV
Bypass Valves
HRN
Horn
CAL
Calibrate
HS
High RPM
CAN
CAN Signal
IGN
Ignition
CAT
CATS Module
JBD
Jib Bellcrank Down
CNK
Chain Break
JBE
Jib Extend
DCN
Drive Chassis Controller
JBR
Jib Retract
DE
Drive Enable
JBS
Jib Sensor
DEL
Drive Enable Left
JBU
Jib Bellcrank Up
DER
Drive Enable Right
JD
Jib Down
DTH
Data High
JER
Jib Extend/Retract Control
DTL
Data Low
JFC
Jib Up/Down Flow Control
EDC
Electrical Displacement Control
JPL
Propel Signal
ENL
Envelope Lockout
JPW
Joystick 5V DC Power
ENV
Envelope Light
JRL
Jib Rotate Left (CCW)
ERL
Extend/Retract Lockout
JRR
Jib Rotate Right (CW)
ESL
Engine Status Lamp
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Wire Circuit Legend
Suffix
Definition
Suffix
Definition
JSV
Jib Select Valve
PLF
Platform Level Flow Control
JU
Jib Up
PLL
Propel Lockout
JUD
Jib Up/Down Control
PLS
Primary Boom Extend/Retract Signal
LDS
Load Sensor
PLU
Platform Level Up
LF
Left Front
PRC
Platform Rotate Control
LFS
Left Front Steer Sensor
PRF
Platform Rotate Flow Control
LO
Lockout
PRL
Platform Rotate Left (CCW)
LOF
Low fuel
PRR
Platform Rotate Right (CW)
LPS
Lamps
PRV
Proportional Valve
LR
Left Rear
PS
Pressure Switches
LRS
Left Rear Steer Sensor
PSE
Program Setup Enable
LS
Limit Switch
PSL
Power to Length Sensor
LS
Low RPM
PSR
Pressure Sender
LSR
Lift Speed Reduction
PTA
Platform Tilt Alarm
MFV
Multi Function Valve
PTS
Platform Tilt Sensor
MS
Motor Shift (Speed)
PUD
Primary Boom Up/Down Flow Control
PBD
Primary Boom Down
PWR
Power
PBE
Primary Boom Extend
PXS
Proximity Sensor
PBL
Primary Boom Extend/Retract Lockout
Valve
RAP
Axle Rear Position
RCV
Recovery
PBR
Primary Boom Retract
REC
Receptacle
PBS
Primary Boom Angle Sensor
RET
Return
PBU
Primary Boom Up
REV
Reverse
PCE
Pressure Comp Enable
RF
Right Front
PCN
Platform Control
RFS
Right Front Steer Sensor
PEL
Primary Ext/Ret Lockout
RL
Retract Lockout
PER
Primary Boom Extend/Retract Flow Control
RPM
RPM
PES
Primary Boom Up/Down Signal
RR
Right Rear
PL
Primary Lockout
PLD
Platform Level Down
Part No. 1268556
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Wire Circuit Legend
Suffix
Definition
Suffix
Definition
RRS
Right Rear Steer Sensor
STR
Starter
RS
Rotary Sensor
SUD
Sec Boom Up/Down Flow Control
SA
Start Aid (Glow Plug or choke)
TAX
Tilt Alarm X axis
SB
Secondary Boom
TAY
Tilt Alarm Y axis
SBD
Sec Boom Down
TCN
Ground Control
SBE
Sec Boom Extend
TCN
Ground Control Panel
SBL
Sec Boom Elevated
TET
Tether
SBR
Sec Boom Retract
TRF
Turntable Rotate Flow Control
SBS
Sec Boom Angle Sensor
TRR
Turntable Rotate Right (CW)
SBU
Sec Boom Up
TS
Temp Switches
SCC
Steering Valve (CCW)
TSR
Temp Sender
SCW
Steering Valve (CW)
TSW
Test Switch
SEN
Sensor
TTA
Turntable Tilt Alarm
SER
Sec Boom Extend/Retract Flow Control
TTS
Turntable Tilt Sensor
SHD
CAN Shield
SLD
Secondary Boom Lockout Valve (riser down)
SLE
Secondary Boom Lockout Valve (extend)
SP
Spare
SS
Speed Sensor
STC
Steer Control Signal
160
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Wire Color Legend
Wire Coloring
1
2
3
All cylinder extension colors are solid and all
retract functions are striped black. When using
black wire, the stripe shall be white.
All rotations that are LEFT or CW are solid,
RIGHT or CCW are striped and black. When
the wire is black, the stripe is white.
All proportional valve wiring is striped.
Color
Circuit #
Primary Function
RD
1
Primary boom up drive
RD/BK
2
Primary boom down drive
RD/WH
3
Primary boom up/dwn FC
proportional valve drive
WH
4
Turntable rotate left valve drive
WH/BK
5
Turntable rotate right valve drive
WH/RD
6
Turntable rotate FC proportional
valve drive
BK
7
Primary boom extend
Wire Color Legend
BK/WH
8
Primary boom retract
BL
Blue
BK/RD
9
BL/BK
Blue/Black
Primary boom Extend/Retract
proportional valve drive
BL/RD
Blue/Red
BL
10
Secondary boom up valve drive
BL/WH
Blue/White
BL/BK
11
Secondary boom down valve
drive
BK
Black
BL/WH
12
BK/RD
Black/Red
Secondary boom up/dwn FC
proportional valve drive
BK/WH
Black/White
BL/RD
13
Drive enable
BK/YL
Black/Yellow
OR
14
Platform level up valve
BR
Brown
OR/BK
15
Platform level down valve
GR
Green
OR/RD
16
GR/BK
Green/Black
Platform up/dwn FC proportional
valve drive
GR/WH
Green/White
GR
17
Platform rotate left valve driver
RD
Red
GR/BK
18
Platform rotate right valve driver
RD/BK
Red/Black
GR/WH
19
Jib select valve driver circuit
RD
20
12 battery supply
WH
21
12 ignition supply
BK
22
Keyswitch power to platform
ESTOP
WH
23
Power to platform
RD
24
Power to warning senders
WH/BK
25
Power to oil pressure sender
WH/RD
26
Power to temp sender
RD/WH
Red/White
OR
Orange
OR/BK
Orange/Black
OR/RD
Orange/Red
WH
White
WH/BK
White/Black
WH/RD
White/Red
YL
Yellow
Part No. 1268556
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Wire Color Legend
Color
Circuit #
Primary Function
Color
Circuit #
Primary Function
RD
27
Auxiliary power
GR
61
Axle retract
RD/BK
28
Platform level alarm
OR
62
Boom stowed (safety)
RD/WH
29
Drive motor shift (speed)
OR/RD
63
WH
30
Forward/EDC-A
Power to boom envelope safety
switch
WH/BK
31
Reverse/EDC-B
OR/BK
64
Power for operational switches
65
Low fuel indication
WH/RD
32
Brake
BL/WH
BK
33
Start
BL
66
Drive enable
BK/WH
34
Start aid (glow plug or choke)
BL
67
Secondary boom not stowed
RD
68
Primary boom lowered
(operational)
BL
69
Primary boom #1 extended
BL/WH
70
Primary boom #2 retracted
BL/BK
71
Primary boom #2 extended
GN
72
Secondary boom extend
GN/BK
73
Secondary boom retract
RD
74
Primary #1 Lockout
RD/WH
75
Primary #2 Lockout
BL
76
Pri boom #3 extended
WH
77
Lower angle #1 operational
WH/BK
78
Upper angle #2 operational
BK
79
power from TCON ESTOP
N/A
80
Can 2.0/J1939 Shield
GR
81
Can 2.0/J1939 Low
YL
82
Can 2.0/J1939 High
GR/WH
83
Tilt signal x axis
GR/BK
84
Tilt signal y axis
GR
85
Tilt sensor power
OR
86
Hydraulic filter restricted
BK/RD
35
High engine speed select
BL
36
Steer clockwise
BL/BK
37
Steer counterclockwise
BL/WH
38
Gas
BL/RD
39
LP
OR
40
Limit switch signal stowed
OR/BK
41
RPM signal
OR/RD
42
Boom retracted signal
GR
43
Jib up
GR/BK
44
Jib down
GR/WH
45
AC Generator
WH
46
Drive horn
WH/BK
47
Output power enable
WH/RD
48
Work lamp
WH/BK
49
Motion lamp
BL
50
Auxiliary boom
BL/WH
51
Auxiliary steer
BL/RD
52
Auxiliary platform
WH/BK
53
Boom envelope safety valve
cutoff
BK/WH
54
Power to safety interlock
switches (engine)
RD
87
Platform level safety power
RD/BK
88
Platform level safety output
GR/BK
55
Axle oscillation
BR
89
Platform level safety ground
RD
56
Foot switch/TCON estop power
RD/BK
90
Proximity kill
RD/WH
57
Boom down safety interlock
RD/WH
91
Gate Interlock
RD/BK
58
Safety interlock to engine
WH/BK
92
Motor speed (LO/HI)
GR/WH
59
Chain break circuit
WH/RD
93
Motor bypass
GR/WH
60
Axle extend
WH
94
Load sensor
OR
95
Tether ESTOP return
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Wire Color Legend
Color
Circuit #
Primary Function
RD
96
Tether power
BK
97
Tether ESTOP power
WH
98
Color
Circuit #
Primary Function
WH/BK
126
Secondary boom lockout (Riser
Down Enable)
J1708 + (high)
GR
127
ECU test switch
128
Low engine speed
BK
99
J1708 - (low)
OR/RD
WH/RD
100
Outrigger lowered
RD/BK
129
Descent alarm
130
Travel alarm
WH/BK
101
Outrigger raised
WH/RD
OR
102
Pothole protector up
BL
131
Motion alarm
OR/RD
103
Pothole protector down
GR
132
Platform load input
133
Platform load alarm
BK/WH
104
Proprietary data buss – (i.e. ITT
or AP)
GR/WH
GR/BK
134
Key switch power
BK/RD
105
Proprietary data buss + (i.e. ITT
or AP)
BL/WH
135
Fuel pump
RD
136
Power to safety module
GR
106
Spare
RD/WH
137
Propel power (P_38)
RD
107
Alternator field
RD/BK
138
BL/WH
108
Engine status
Pri boom up/sec boom dwn-Ext
(P_11/30)
GR/WH
109
Sensor pwr
WH/RD
139
Turntable rot FC safety (P_39)
BK
110
Sensor return
OR/RD
140
Boom envelope safety
OR
111
Steer signal
RD
141
RD
112
Steer signal to solenoid valve
Primary boom angle signal
safety
OR/RD
113
Multi function valve
OR
142
BK/RD
114
Load moment overweight
Secondary boom angle signal
safety
RD/BK
115
Load moment underweight
BL/RD
143
Drive enable left
OR
116
Hydraulic oil cooler
BL/WH
144
Drive enable right
RD
117
Flashing beacon
RD/WH
145
Calibrate
OR
118
Lift speed reduction
BL
146
Jib bellcrank up FC
BL
119
Hydraulic pressure sensor output
BL/BK
147
Jib bellcrank down FC
OR
120
Oil cooler fan
BL/WH
148
Jib bellcrank sensor
GR
121
Axle oscillate LEFT
GR/WH
149
Jib Up/Down FC
GR/BK
122
Axle oscillate RIGHT
GR/BK
150
Hydraulic generator bypass
RD/BK
123
Primary boom angle signal
operational
GR
151
Hydraulic EDCoutput
BK
152
Injector retard
RD/WH
124
Secondary boom angle signal
operational
BK
153
Jib extend
BK/WH
154
Jib retract
Secondary boomlockout (Ext
Enable)
OR/RD
155
Pressure comp enable
GN/WH
156
Jib Up/Down
BK/RD
157
Jib Ext/Ret
WH/RD
125
Part No. 1268556
163
Service and Repair Manual
September 2016
Wire Color Legend
Color
Circuit #
BL/RD
158
Spare
WH
185
Encode A
BL/WH
159
Steer joystick signal
BL
186
Encode B
WH/RD
160
Propel joystick signal
BL
187
Bootstrap or program enable
WH/BK
161
Sec boom joystick signal
GR
188
Safety cross check
OR
162
Joystick 5 VDC power
BK
189
Data receive
BL/WH
163
Pri extend/retract signal
BK/WH
190
Data transmit
RD/WH
164
Pri up/down signal
WH/RD
191
Multi-Function pressure relief
WH/RD
165
TT Rotate signal
WH/BK
192
Jib rotate left
OR
166
Boom length signal safety
WH/RD
193
Jib rotate right
OR/BK
167
Boom length signal operational
WH/RD
194
Speed select input
BL/RD
168
Primary boom hydraulic valve
lockout
OR/RD
195
Electric brake source
YL
196
2.5V Sensor power
GN
169
Envelope active LED
BR
N/A
Ground or return
WH/RD
170
Load sense relay source
WH/BK
171
Load sense relay sink
BL
172
UP/DN flow control ground
BK
173
Ext/Ret flow control ground
WH
174
Key switch power, ground
position
WH/BK
175
Load sensor signal operational
GN/WH
176
Secondary extend/retract FC
BL/RD
177
Extend/retract lockout
BK
178
Control module status light
GN
179
Drive power relay
BK
180
Lift power relay
OR
181
48 Volt alternator field (or
battery)
RD
182
24 Volt battery
BL
183
Envelope or load sense recovery
WH
184
Program setup enable
164
Primary Function
Color
Circuit #
Primary Function
Part No. 1268556
September 2016
Service and Repair Manual
Wire Color Legend
Types of Limit Switches
Types of Limit Switches
There are two types of limit switches, found in
various locations throughout the machine:
mechanical-type operational or safety switches.
As in aircraft, which features redundant safety
systems, each mechanical operational switch is
backed up with a separate, independently
functioning safety switch.
LSP1AO
Primary boom angle stowed
LSP1RO
Primary boom length retracted
LSP1EO
Primary boom length fully extended
LSS1AO
Secondary boom angle, fully stowed
LSS2AO
Secondary boom angle, fully raised
LSS3AO
Secondary boom angle, 25° to 30°
The mechanical-type operational or safety
switches are used to sense a positive
displacement or movement of the limit switch
actuator, or arm, as the machine moves through its
range of operational functions. Included in this
group are envelope limit switches which sense the
extended length and angle of the booms and
rotational position of the turntable.
LSS2AS
Secondary boom angle safety
LSS1RO
Secondary boom fully retracted
LSS1RS
Secondary boom fully retracted, safety
LSJ1EO
Platform level fully extended
LST1O
Drive enable mechanical
LSA1OS
Oscillate axle, right side
LSA2OS
Oscillate axle, left side
For example, when the secondary boom is fully
raised and the operational switch is activated, it
tells the ECM at the ground controls to start
extending the secondary boom.
Another example is the drive enable limit switch,
which disables the drive function anytime the boom
is rotated past the rear axles, indicated by the
'circle' end of the drive chassis.
Numbering Legend
LS
LS
Limit
Switch
P
J
1
Jib Boom
Circuit
Number
R
A
O
Angle
O
Operational
S
Safety
P
Boom
D
Down
T
Turntable
E
Extend
R
Retract
In some cases, the engine will be stopped if safety
parameters are exceeded.
Part No. 1268556
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Service and Repair Manual
September 2016
Limit Switches and Angle Sensors
Limit Switch Legend
1
LSP1RO
9
2
LSS2AO
10 LSA1OS
3
LSP1EO
11 LSA2OS
4
LSP1AO
12 LST1O
5
LSJ1EO
13 Turntable Angle Sensor
6
Platform Angle Sensor
14 LSS1AO
7
LSS1RO
15 LSS1RS
8
LSS3AO
16 Primary Boom angle Sensor
166
LSS2AS
Part No. 1268556
September 2016
Service and Repair Manual
Schematics
Limit Switch Functions
LSA1OS: Limit switch, Axle #1 Oscillating
Operational. Activates the axle oscillate circuit on
the right side.
LSA2OS: Limit switch, Axle #2 Oscillating
Operational. Activates the axle oscillate circuit on
the left side.
LST1O: Limit switch, Operational. Activates the
drive enable zone.
Turntable Angle Sensor: Measures the X axis and
Y axis of the turntable. The alarm sounds at
4.5 degrees.
Primary Boom Angle Sensor (PBS): Measures
the Y axis angle of the primary boom. The
operational range shall be +33 degrees to
+73 degrees. The safety cutouts are set at
+70 degrees and will disable boom up and stop the
engine.
LSS2AS: Limit switch, Secondary Boom #2 Angle
Safety Switch. Secondary boom angle full
extension, angle up all the way (secondary boom
extend allowed). Backup switch for LSS2AO.
LSS1RO: Limit switch, Secondary Boom #1 Retract
Operational Switch. Secondary boom fully retracted
(secondary boom down allowed).
LSS1RS: Limit switch, Secondary Boom #1 Retract
Safety Switch. Secondary boom fully retracted
(secondary boom down allowed). Backup switch for
LSS1RO.
LSS1AO: Limit switch, Secondary Boom #1 Angle
Operational Switch. Open when the secondary
boom is fully lowered, closes when the boom is
raised out of the stowed position. This switch limits
the drive speed and disables the drive motor
destroke. The other contacts close when the boom
is fully lowered allowing the platform to be tucked
underneath the mast for transport.
Platform Angle Sensor: Measures the angle of the
platform. The range of measurement is +/20 degrees. The safety cutout is set at +/10 degrees from gravity and will disable the primary
and secondary boom up/down functions and the
platform level up/down functions.
LSP1AO: Limit Switch, Primary Boom #1 Angle
Operational. One side closes when the primary
boom is raised from the stowed position, disabling
the drive motor destroke and limiting the drive
speed. The other side of the switch closes when the
boom is fully lowered allowing the platform to be
tucked underneath the mast for transport.
LSS2AO: Limit switch, Secondary Boom #2 Angle
Operational Switch. Secondary boom angle full
extension, angle up all the way (secondary boom
extend allowed).
LSJ1EO: Limit Switch, Jib Boom #1. Closes when
the platform leveling cylinder is fully extended,
disabling the primary boom down function.
LSS3AO: Limit switch, Secondary Boom #3 Angle
Operational Switch. Secondary boom elevated to
30-35 degrees. Used to switch platform/primary
boom leveling parameters.
LSP1EO: Limit Switch, Primary Boom #1 Extend
Operational. Switch closes as the primary boom
extends the last 6 to 12 inches signaling the
computer.
LSP1RO: Limit Switch, Primary Boom #1 Retract
Operational. Switch closes when the primary boom
is fully retracted.
Part No. 1268556
167
Service and Repair Manual
September 2016
Drive Chassis and Platform Controller Pin Legend
Pin Numbering - 23 pin connector
J21
Plat Controller
J22
Plat Controller
J31
Drive Chassis
J32 Drive Chassis
1
GND PCON - BR
1
VLVRET7 - BR
1
GND-DCON - BR
1
VLVRET - BR
2
P52PCON - BL/RD
2
(UNUSED)
2
P21DCON - WH
2
V61AXRT - GR
3
(UNUSED)
3
C17PRL - GR
3
P53LS - RD
3
4
S56PRV - RD
4
C18PRR - GR/BK
4
(UNUSED)
V60AXEX GR/WH
5
(UNUSED)
5
C43JU - GR
5
S56PRV - RD
4
V29MS - RD/WH
(UNUSED)
6
(UNUSED)
6
C44JD - GR/BK
6
C61AXRT - GR
5
7
P56PRV - RD
7
C14PLU - OR
7
(UNUSED)
6
V52AFV - BL/RD
V52REV - BL/RD
8
(UNUSED)
8
C15PLD - OR/BK
8
AXLE RET GND
7
9
(UNUSED)
9
(UNUSED)
9
C61LS - GR
8
V36RRS - BL
10
D80SHIELD
10
R90PXS - RD/BK
10
D80SHLD
9
V37RRS - BL/BK
C111RRS - OR
11
(UNUSED)
11
C90PXS - RD/BK
11
RS232 RXD
10
12
(UNUSED)
12
(UNUSED)
12
RS232 TXD
11
C111LRS - OR
C111RFS - OR
13
(UNUSED)
13
(UNUSED)
13
BOOT
12
14
(UNUSED)
14
(UNUSED)
14
(UNUSED)
13
C111LFS - OR
VLVRET2 - BR
15
C47OUT - WH/BK
15
C88PTS - RD/BK
15
C61LS(A) - GR
14
16
C46HRN - WH
16
R56PTS - RD
16
(UNUSED)
15
V32BRK - WH/RD
17
D81CAN(-) - GR
17
C56PTS - RD
17
D81CAN(-) - GR
16
V36LRS - BL
V37LRS - BL/BK
18
D82CAN(+) - YL
18
S14PLU - RD
18
D82CAN(+) - YL
17
19
(UNUSED)
19
PLATRET - BR
19
RS232 GND
18
V36RFS - BL
P110RT - BK
20
(UNUSED)
20
C84TAY - GR/BK
20
(UNUSED)
19
21
(UNUSED)
21
P85PTS - GR
21
(UNUSED)
20
22
(UNUSED)
22
PTSRET - BR
22
(UNUSED)
P109ANG GR/WH
23
P23PCON - BK
23
P87PTS - RD
23
C61LS(A) - GR
21
V37RFS - BL/BK
22
V36LFS - BL
23
V37LFS - BL/BK
168
Part No. 1268556
September 2016
Service and Repair Manual
Turntable Controller Pin Legend
Pin Numbering - 35 pin connector
Pin Numbering - 23 pin connector
Turntable Controller
1
GNDDCON - BR
2
P21DCON - RD
1
Vl.VRET1 - BR
1
VLVRET4 - BR
P52PCON - BL/RD
3
P53LS - WH/BK
2
C35RPM – BK/RD
2
C03PBF - RD/WH
3
C46HN - WH
4
P54ENG - BK/WH
3
C211GN - WH
3
C09PERF - BK/RD
4
C470UT - WH/IIK
5
S56PRV - RD
4
C34SA - BK/WH
4
C061RF - WH/RD
5
P23PCON – BK
6
P21DCON - RD
5
V30FWD - WH
5
C12FBFC – BL/WH
6
S56PRV - RD
7
P58LS - RD/BK
6
V31REV - WH/BK
6
C72SBE – BL/WH
7
P56PRV- RD
8
S59SBE - GR/WH
7
C48HN - WH
7
C01PBU - RD
8
R48LP- WH/RD
9
S121PBU - GR
8
C39LP - BL/RD
8
C02PBD – RD/BK
9
R49LP- WH/BK
10
P53LS - WH/BK
9
C33STR - BK
9
C07PBE - BK
10
D080-SHIELD
11
P53LS - WH/BK
10
C30EDC - WH
10
COSPBR - BK/WH
11
(UNUSED)
12
S59SBE - GR/WH
11
C31EDC - WH/BK
11
(UNUSED)
12
(UNUSED)
13
C64LS - OR/BL
12
C25PSR - WH/BK
12
C115SD – BL/BK
13
(UNUSED)
14
C65LOF - BL/WH
13
C26TSR – WH/RD
13
R49LP – WH/BK
14
S132LDS-BL/WH
15
C66DREN- BL
14
RET85TTSR - GR
14
VLVRET5 -BR
15
P97TET- BK
16
C73SBR - BL/RD
15
P85TTSR - GR
15
S73SLD – GR/BK
16
(UNUSED)
17
C68PBD- RD
16
VLVRET2 - BR
16
(UNUSED)
17
DS1CAN(-) - GR
18
C64LS - OR/BL
17
(UNUSED)
17
S10SLE - BL
18
DS2CAN(+) - YL
19
C70PBR - BL/WH
18
C41RPM - OR/BK
18
C114LS – BK/RD
19
(UNUSED)
20
C71PBE - BL/BK
19
(UNUSED)
19
(UNUSED)
20
TETFUNC - WH
21
C67S8D - BL
20
C83TAX- GR/WH
20
C73SBR - BL/RD
21
TETGND - BR
22
C77SBU - WH
21
C84TAY- GR/BK
21
C72SBE – BL/WH
22
P96TET - RD
23
V74PRLO - RD
22
C45GEN- GR/WH
22
(UNUSED)
23
P95TET - OR
V75PRLO RD/WH
23
VLVRET3 - BR
23
C113MFV – OR/RD
Turntable
Controller
1
GNDPCON - BR
2
Part No. 1268556
24
J13
Pin Numbering - 4 pin connector
J12
J11
Turntable
Controller
J14 Turntable
Controller
J15
Turntable
Controller
24
(UNUSED)
25
SNSR GND - BR
25
C04TRL - WH
26
BOOM ANGLE
PWR
1
BATVLV - RD
28
COSTRR - WH/BK
2
BATGND - BR
27
Vl.VRTN7 - BR
27
G119SR - BL
3
BATGND - BR
28
(UNUSED)
28
C124SBL - RD/BK
4
BATECU - RD
29
(UNUSED)
29
C77AS - WH
30
VLVRETS - BR
30
C78PS - WH/BK
31
(UNUSED)
31
P56PRV - RD
32
C27AUX - RD
32
PRIMARYANGLE
SENSOR INPUT
33
P125SBLE WH/RD
33
SEC.ANGLE
SENSOR INPUT
34
P128SBLD –
WH/BK
34
P30
35
(UNUSED)
35
VLVRET1 - BR
169
Service and Repair Manual
September 2016
Relay and Fuse Panel Legends
170
Part No. 1268556
September 2016
Service and Repair Manual
Relay and Fuse Panel Legends
Part No. 1268556
171
Service and Repair Manual
September 2016
Electrical Symbol Legend
Battery
Coil, solenoid or relay
Horn or alarm
Flashing beacon
Gauge
Diode
Hour meter
LED
Fuse with amperage
Foot switch
T-circuits connect
Limit Switch
Power relay
Coil with suppression
Fuel or RPM solenoid
Connection - no terminal
T-circuits connect at
terminal
Circuits crossing - no
connection
Quick disconnect
terminal
Circuit breaker with
amperage
Key switch
Toggle switch DPDT
Toggle switch SPDT
Pump or Motor
Tilt sensor
Battery seperator
Gauge sending unit
Control relay contact
normally open
Diode starting aid, glow
plug or flame ignitor
Horn button - normally
open
Oil temperature switch
normally open
172
Emergency stop button Resistor with ohm value
normally closed
Coolant temperature
switch - normally open
Oil pressure switch
normally closed
Part No. 1268556
September 2016
Service and Repair Manual
Hydraulic Symbols Legend
Orifice with size
Check valve
Shut off valve
Brake
Pump, fixed displacement
Pump, bi-directional
variable displacement
Motor, bi-directional
Motor, 2 speed
bi-directional
Double acting cylinder
Pump, prime mover (engine
or motor)
Shuttle valve. 2 position,
3 way
Differential sensing valve
Filter with bypass relief
valve
Relief valve with pressure
setting
Priority flow regulator valve
Solenoid operated
proportional valve
Directional valve
(mechanically activated)
Flow divider/combiner valve
Pilot operated 3 position,
3 way shuttle valve
Solenoid operated
2 position, 3 way directional
valve
Counterbalance valve with
pressure and pilot ratio
Solenoid operated
3 position, 4 way directional
valve
Solenoid operated
3 position, 4 way
proportional directional
valve
2 position, 2 way solenoid
valve
Part No. 1268556
173
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options,
Deutz TD2.9 Engine
174
September 2016
Service and Repair Manual
Electrical Schematic - Engine Options, Deutz TD2.9 Engine
Part No. 1268556
175
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options, Deutz TD2.9 Engine Harness
176
Part No. 1268556
September 2016
Electrical Schematic - Engine Options,
Deutz TD2.9 Engine Wiring
177
Service and Repair Manual
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options,
Perkins 404F-22T Engine
178
September 2016
Service and Repair Manual
Electrical Schematic - Engine Options, Perkins 404F-22T Engine
Part No. 1268556
179
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness
180
Part No. 1268556
September 2016
Electrical Schematic - Engine Options,
Perkins 404F-22T Engine Wiring
181
Service and Repair Manual
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options,
Perkins 804D Engine
182
September 2016
Service and Repair Manual
Electrical Schematic - Engine Options, Perkins 804D Engine
Part No. 1268556
183
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options, Continental TME27 Engine
184
Part No. 1268556
September 2016
Electrical Schematic - Engine Options,
Continental TME27 Engine
185
Service and Repair Manual
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options,
Perkins 804D Engine
186
September 2016
Service and Repair Manual
Electrical Schematic - Engine Options, GM 3.0 Engine
Part No. 1268556
187
Service and Repair Manual
September 2016
Electrical Schematic - Engine Options,
GM 3.0 Engine
188
Part No. 1268556
September 2016
Service and Repair Manual
Electrical Schematic - Safety Circuits
Part No. 1268556
189
Service and Repair Manual
September 2016
Electrical Schematic - Safety Circuits
190
Part No. 1268556
September 2016
Service and Repair Manual
Electrical Schematic - Generator Options
Part No. 1268556
191
Service and Repair Manual
September 2016
Electrical Schematic - Generator Options
192
September 2016
Electrical Schematic - Welder Generator Option
193
Service and Repair Manual
Service and Repair Manual
September 2016
Electrical Schematic - Welder Generator Option
194
Part No. 1268556
September 2016
Service and Repair Manual
Electrical Schematic - Hydraulic Generator Options
Part No. 1268556
195
Service and Repair Manual
September 2016
Electrical Schematic - Hydraulic Generator Options
196
September 2016
Hydraulic Schematic 2 Wheel Drive (2 and 4 Wheel Steer)
197
Service and Repair Manual
Service and Repair Manual
September 2016
Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)
198
Part No. 1268556
September 2016
Service and Repair Manual
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)
Part No. 1268556
199
Service and Repair Manual
September 2016
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)
200
DCON PWR RD
P6R1
WH/BK
1
1
2
2
1
1
2
2
S56PRV-RD
S56PRV-RD
GND DCN-BR
GNDDCN-BR
P21DCN-WH
P21DCN-WH
P53LS-WH/BK
P53LS-WH/BK
PRI BOOM ANG SENSOR
WHT
21
22 21
NC
14 13
NO
WHT
4321
22 21
NC
14 13
NO
654321
12
11
NC
22 21
NC
13 14
NO
YEL
11
NC
22 21
NC
13 14
NO
PUR
12
654321
22
ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION
21
NC
14 13
ORN NO
21
RED
14 13
NO
24 23
22 21
NC
14 13
BLU NO
NO
4321
21
NC
14 13
GRN NO
22
4321
4321
21
NC
14 13
BRN NO
22
B2
B1
ENGINE
BLOCK
AUX.
PUMP
BAT.
+
D2
ALTERNATOR
BAT.
-
STA.
REGULATOR IND.
EXCT.
D1
86 CR5
HORN
87a 87 85 RELAY
J57
1
2
3
A B C D
CR15 86
ST AID
RELAY 85
H1
30
87 87a
85
OTS1N.O.
LINE BK
CR17
30 OIL
87 87a COOLER
RELAY
D5
R21IGN-WH
J120
FAN
D8
DUETZ TD2011L04i ENGINE SHOWN
C27AUX-RD
C25PSR-WH/BK
P126SBLD-WH/BK
B1ENG-RD
C21IGN-WH
30 86 CR28
ENG ALT
87a 87 85 RELAY
P P P
1 30
87a 3
87
4
2 86 85 5
D7
P
D3
TURNTABLE_ROTATE_VLV
PRI_EXTEND_VLV
PRI_RET_VALVE
P4-08
P4-09
P4-10
C02PBD-RD/BK
C07PBE-BK
C08PBR-BK/WH
SEC_RET_VLV
P4-19
P4-20
C10SBU-BL
C73SBR-BL/RD
C04TRL-WH
C05TRR-WH/BK
P4-30
SEC BOOM DOWN SEQ #2 VALVE
P4-33
P4-34
P125SBLE-WH/RD
P126SBLD-WH/BK
P4-35
AUX_RELAY
TO
MICRO
SEC BOOM EXT SEQ #1 VLV
TO PLD
TO PLD
TO
TO
TO
MICRO MICRO MICRO
P4-32
TO PLD
TO PLD
P7R
P4-31
TO MICRO
TO
MICRO
P4-29
VALVE_RTN6
ROTATE_CCW_VLV
VALVE_RTN7
P4-27
P4-28
ROTATE_CW_VLV
P4-26
MULTI_FUNCT_VLV
P4-25
P4-24
P4-23
P4-22
C72SBE-BL/WH P4-21
SEC_EXT_VLV
SEC_UP_VLV
P4-18
LSS2AS MONITOR INPUT
SPARE
SPARE
P4-16
P4-17
S10SLE-BL
LSS1RS MONITOR INPUT
VALVE_RTN5
DRIVE LIGHTS RELAY
P4-15
P4-14
VLVRET5-BR
S73SLD-GR/BK
P4-12
P4-13
C11SBD-BL/BK
R49LP - WT/BK
SEC_DWN_VLV
PRI_DOWN_VLV
P4-07
C01PBU-RD
P4-11
SEC. BOOM F.C.
PRI_UP_VLV
P4-06
C12SBFC-BL/WH
P4-05
BOOM_EXT/RET_VLV
P4-04
C27AUX-RD
P125SBLE-WH/RD
P126SBLD-WH/BK
C27AUX-RD
S73SLD-GR/BK
VALVE RTN6
NEUTRAL WH
VALVE RTN6
RD/12VDC
VALVE RTN7
NEUTRAL WH
VALVE RTN7
V126SBLD-WH/BK
S10SLE-BL
P125SBLE-WH/RD
C05TRR WH/BK
WH
C10SBU-BL
C73SBR-BL/RD
C72SBE-BL/WH
NC
C04TRL-WH
V126SBLD-WH/BK
TO DRIVELAMPS
V125SBLE-WH/RD
TO
MICRO
C10SBU-BL
C73SBR-BL/RD
C72SBE-BL/WT
P126SBLD-WH/BK
V125SBLE-WH/RD
P34 J34
S10SLE-BL
1
P125SBLE-WH/RD
2
P126SBLD-WH/BK
3
V125SBLE-WH/RD
4
V126SBLD-WH/BK
SEC EXT VLV (J65)
P125SBLE-WH/RD
SEC UP VLV (J67)
P125SBLE-WH/RD
P126SBLD-WH/BK
TO
MICRO
SEC RET VLV (J66)
S73SLD-GR/BK
S10SLE-BL
TO
MICRO
12 VOLT
S73SLD-GR/BK
S10SLE-BL
TO
MICRO
R49LP - WT/BK
C26TSR-WH/RD
P4-03
P_30
SEC DWN VLV (J68)
P116HYD-OR
C11SBD-BL/BK
FIELD BK/WH
TO
MICRO
VLVRET5-BR
BK
BK
15A- 120VAC GENERATOR
12.5A- 220VAC GENERATOR
C08PBR-BK/WH
BK
PRI RET VLV (J63)
FIELD BK/WH
C07PBE-BK
GN
PRI EXT VLV (J62)
BR GND
TO PLD
J9
J10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
PRI BOOM LENGTH 3' STATUS
TT ROT CW VLV (J70)
86
LINE BK
C02PBD-RD/BK
BR
PRI DWN VLV (J60)
GND BR
C01PBU-RD
AUTO
RESET CB
OPTIONAL 120VAC W/REGULATOR
C12SBFC-BLU/WT
WH
4
X
TT ROT CCW VLV (J71)
B
87
C06TRF-WH/RD
TURNTABLE
TILT SENSOR
PRI UP VLV (J59)
6
C09PERF-BK/RD
DUETZ TD2011L04i ENGINE SHOWN
SEC. BM F.C. (J64)
5
TO
MICRO
C06TRF-WH/RD
RET85TTSR-BR
MANIFOLD HARN
C09PERF-BK/RD
P85TTSR-GR
J14 WHITE 35 PIN
PRI BM EXT/RET F.C. (J61)
2 86 85 5
4
BOOM_UP/DOWN_VLV
J31-TILT SNSR
VALVE_RTN4
P31-ENG HARN
P4-02
TCON
P4-01
PERKINS 804D ENGINE- SEE ENGINE OPTION PAGE
CONTINENTAL TME27 ENGINE- SEE ENGINE OPTION PAGE
DEUTZ TD2.9 SEE ENGINE OPTION PAGE
PERKINS 404TF SEE ENGINE OPTION PAGE
VLVRET4-BR
P_11
C03PBF-RD/WH
TO PLD
P10
C03PBF-RD/WH
BR
3
VLVRET4-BR
87a
W
TT ROT CW/CCW F.C. (J69)
RD-HOLD
1 30
3
V125SBLE-WH/RD
C83TAX-GR/WH
RET85TTSR-BR
(EXT ENABLE) SEC BM EXT SEQ #1
P85TTSR-GR
+
+
-
V126SBLD-WH/BK
C84TAY-GR/BK
2
(DWN ENABLE) SEC BM DN SEQ #2
C83TAX-GR/WH
1
REGULATOR
7
VOLTAGE
C84TAY-GR/BK
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
P22R
C26TSR-WT/RD
74HC08 13
C25PSR-WT/BK
AC GENERATOR
P1-23 VALVE_RTN3
P1-22
P1-21 TT_TILT_Y_AXIS
P1-20 TT_TILT_X_AXIS
P1-19
P1-18 ALTERNATOR RPM
P1-17 AC GENERATOR
P1-16 VALVE RTN_2
P1-15 TT_TILT_SNSR_PWR
P1-14 TT_TILT_SNSR_GND
P1-13 OIL/WATER_TEMP
TO HORN BUTTON
(P15)+(ECU POWER)
P22R
C21IGN-WH
B1ENG-RD
EDC REV
P1-12 OIL_PRESSURE
P1-11
P1-10 EDC FWD
V
PRI BM UP/DN F.C. (J58)
30
C45GEN GN/WH
R21IGN-WH
C41RPM-OR/BK
VLVRET2-BR
C26TSR-WH/RD
C25PSR-WH/BK
C31EDC-WH/BK
P_7
P7R
TO
MICRO
OIL TEMP SENDER
C
P1-09 STARTER RELAY
P1-08
P6R1
P_9B
OIL PRESSURE
S-500
C30EDC-WH
C33STR-BK
P1-07 SERVICE HRN
P1-06 REV
P1-05 FWD
U95
BAT GND-BR
AUX+
U
FUEL SOLENOID
4321
P34SA-BK/WH
R116HYD-OR
NOTE: FOR ACTIVE LOW
TELEMATICS SYSTEMS
C229TEL IS CONNECTED TO
B2BAT+ STUD ON RELAY BLOCK
(ACTIVE HIGH SHOWN)
BAT GND-BR
GND-
WH-PULL IN
C21IGN-WH
C229TEL-BL/BK
30A
HYDRAULIC
OIL COOLER FAN
A
P32-GEN HARN
B1BAT RD
P116HYD-OR
C45GEN-GR/WH
C116HYD-WH
BAT+
BAT GND-BR
J32-ENG HARN
COOLER
RELAY
P34SA-BK/WH
TO
MICRO
TEMP SW
TROMBETTA
TIME DELAY
MOM N.O.
R34SA-BK/WH
P116HYD-OR
GLOW PLUG
F7 OIL COOLER
F20 HI/LO RPM
F22 GLOW PLUG
F23 ENG/ST/ALT
C34SA-BK/WH
P128 J128
S73SLD-GR/BK
VLVRET-BR
87a
GLOW PLUG
RELAY
85
C31EDC-WH/BK
C226TEL-BL
C30EDC-WH
GND04-BR
30
P1-04 START ASSIST
(~SM)+(AH)
T
DUAL COIL
EDC
STARTER
12
GND04-BR
CR1
30 86
STARTER
87a 87 85
RELAY
86
CB7
15A
22
ENGINE HARN
BATGND(A) - BK
6 AMP
TO
MICRO
BK
C124SBL RD/WH
C68PBD-RD
J13 WHITE 23 PIN
P1-03 IGN/FUEL
TO
MICRO
PULL IN
21
NC
14 13
BRN NO
TO MICRO
WH-PULL IN
CB9
CR80
TELEMATICS
RELAY
TO
MICRO
WH
P53LS-WH/BK
J224 GREY 8 PIN
TELEMATICS
5V 12V
GND
HOLD
S59SBE-GR/WH
74HC08
TROMBETTA
HI/LO SPEED
SOLENOID
ENGINE CAN
BUS TO CAN
GATEWAY
14
RD-HOLD
P58LS-RD/BK
U32
RD
C64LS-OR/BK
TELEMATICS OPTION
ADDED AT SERIAL NUMBER
Z8013-4765
(TM)(FE)
P_7
VLVRET2-BR
C73SBR-BL/RD
C66DREN-BL
P_6R2
P1-02 THROTTLE
TCON MODE
P_7
10
P46HRN(A)-WH
S56PRV-RD
POWER HARN
(~SM)+(AH)
C41RPM-OR/BK
GNDDCN-BR
OUT PWR ENABLE (OE)
C46HRN-WH
J15 BLACK 4 PIN
74HC08
C107AF-RD
P_22
((~SM)+(AH))(P_7) 8
9
C34SA-BK/WH
TCON
P22R
C21IGN-WH
P_11
BTS650
Vbb
OUT
IN
IS
P1-01 VALVE RTN#1
PCON POWER
C35RPM-BK/RD
P11
((~SM)+(AH))(P_22) 11
C27AUX-RD
P11
P7R
C35RPM-BK/RD
P6R1
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
P1-04 BATECU-PWR
BOOM STOWED
C33STR-BK
BTS650
Vbb
OUT
IN
IS
P1-03 BATECU GND
J127 LOADSENSE LED
P_7
P_22
B1BAT-RD
P9A
P6R1
(~SM)+(AH)
(BM STOWED)
GND-BR
PCON POWER
BTS650
Vbb
OUT
IN
IS
30 A
B1ENG-RD
P_1
P10
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
P1-02 SYS BAT GND
P_6R2
GND-BR
TO
MICRO
CB
OUT PWR ENABLE
20A
P_30
TO HORN BUTTON
P1-01 SYS_BAT_PWR
TO HORN BUTTON
B1BAT-RD
(P15)+(ECU POWER)
20 A
F23
P10
P35RPM-BK/RD
(P15)+(ECU POWER)
B1BAT-RD
BOOM UP/DWN FC RECOVERY SIGNAL
F22
TO HORN BUTTON
P_6R2
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
60 A
F20
P7R
20 A
P_7
AUX MAIN
P7R
10
B2BAT-RD
74HC08
RD
TCON MODE
P_7
RD
G-P MODE GR/BK
BOOM DWN RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BAT GND-BR
21
NC
14 13
GRN NO
F7
2
8
P33STR-BK
RD
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
RD
C77SBU-WH
((~SM)+(AH))(BM STOWED)
9
PR1
22
C64LS-OR/BK
C68PBD-RD
C64LS-OR/BK
C77SBU-WH
V125SBLE-WH/RD
P125SBLE-WH/RD
C67SBD-BL
1
RD
4321
WH
BK
BR
RD
C64LS-OR/BK
C77SBU-WH
V125SBLE-WH/RD
P125SBLE-WH/RD
C64LS-OR/BK
C67SBD-BL
C64LS-OR/BK
C73SBR-BL/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
C64LS-OR/BK
P2-35 VLV RET
P9A
P6R1
TO MICRO
TO PLD
WH/BK
BL/WH
BOOM DWN RECOVERY SIGNAL
SERVICE
HORN
ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION
4321
WH
BK
BR
RD
C64LS-OR/BK
C67SBD-BL
C64LS-OR/BK
C73SBR-BL/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
C66DREN-BL
C64LS-OR/BK
P2-34 P_30
P2-33 SEC ANG INPUT
P2-32 PRI ANG INPUT
P2-31 BOOM STOWED
P2-30 LSB14AO
P2-29 LSB13AO
P2-28 DIGITAL IN
TO PLD
TO PLD
B
P23PCON-BK
BL/WH
BOOM RET RECOVERY SIGNAL
BAT GND-BR
22 21
NC
14 13
BLU NO
LSP1AO
> 5 DEG
J43
14 13
NO
24 23
RED NO
LSS2AO
RAISED OPER
J51
21
WH
BK
BR
RD
D82CAN+ -YL
WH
BK
BR
RD
NC
14 13
ORN NO
LSS1AO
5 DEG
J50
22
LSS1RO
SEC RET OPER
J49
WH
BK
BR
RD
S12SBL-BL/WH
C123PBD RD/BK
TO PLD
P2-27 PRESSURE GA
P2-26 SNSR PWR
P2-25 SNSR GND
P2-24 P2 SEQ
P2-23 P1 SEQ
P2-22 LSS2AO
P2-21 LSS1AO
P2-20 LSP1EO
P2-19 LSP1RO
P2-18 LSB2RO
.
P2-17 LSP1AO
P2-16 LSS1RO
P2-15 LST10
P2-14 FST1S
P2-13 OPER SW PWR
BL/BK
C47OUT WH/BK
TCON MODE
OUT PWR ENABLE
S
HORN
RELAY
11
NC
21
NC
13 14
NO
PUR
C64LS-OR/BK
C65LOFL-BL/WH
P58LS-RD/BK
C124SBL RD/WH
P109PBS-GR/WH
SNSR GND-BR
P_14
P2-12 P_18
P2-11
P2-10 P_12
P2-09 P_11
P2-08 P_10
U32
U31
U30
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
MLT FNC VLV O
AUX HYD O
BM DWN ST I
BM 3' I
BM 100' I
PRI LO#1 O
PWR TO TCON ESTOP-BL/BK 1
C47OUT GN/BK
P23PCON-BK
P_22
START BAT
22
C64LS-OR/BK
SJ1-WH/RD
P53LS-WH/BK
S59SBE-GR/WH
P58LS-RD/BK
S59SBE-GR/WH
C77SBU-WH
C67SBD-BL
C71PBE-BL/BK
C70PBR-BL/WH
C64LS-OR/BK
C68PBD-RD
C73SBR-BL/RD
C66DREN-BL
C65LOF-BL/WH
C64LS-OR/BK
P54ENG-BK/WH
P53LS-WH/BK
P53LS-WH/BK
S12SBL-BL/WH
P2-07 P_9B
3
TCON ESTOP-BL/WH 2
TETHER ESTOP-BL/RD
ECU POWER 4
P53LS-BK/WH
C47OUT WH/BK
P223-08 DIGITAL IN 2
P223-07 DIGITAL IN 1
P223-05 MACHINE CAN HIGH
P223-06 MACHINE CAN LOW
P223-04 ENGINE CAN LOW
P223-03 ENGINE CAN HIGH
P223-02 CAN SHIELD
PWR TO TCON ESTOP
AUX HYD
ELECTRONICS
BATTERY
12
C65LOFL-BL/WH
S59SBE-GR/WH
P53LS-WH/BK
P58LS-RD/BK
SJ1-WH/RD
S10SLE-BL
SJ1-WH/RD
P53LS-WH/BK
P58LS RD/BK
P54ENG-BK/WH
P2-06 P_9A
6
OUTPUT PWR ENABLE
S56PRV-RD/BK
SRV REC-WH
P56PRV-RD
OR/BK
GR/WH
OR
S1 PBU-OR
P_7 PLAT-GN/WH
C47OUT WH/BK
P_15-OR/BK
ALM PWR-RD
D81CAN- -GR
D82CAN+ -YL
D228CAN+ YL
D227CAN- GR
J25
J28
J26
J27
P223-01 GROUND
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
1
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
ALTERNATOR
11
NC
21
NC
13 14
NO
YEL
4321
WH
BK
BR
RD
22
4321
WH
BK
BR
RD
WHT
C68PBD-RD
C73SBR-BL/RD
C66DREN-BL
C65LOF-BL/WH
C64LS-OR/BK
P54ENG-BK/WH
P54ENG-BK/WH
S12SBL-BL/WH
P53LS-WH/BK
P2-05 P_7R
P2-04 P_6R2
P2-03 P_6R1
7
P6R1
PCON MODE 5
8
P7R
RD
RD/WH
J228-4
J228-3
ENGINE CAN
BUS TO
TELEMATICS
ALM-GND-BR
MACHINE CAN BUS
TO J152
J228-2
J228-1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW-OR
JSGND4-BR
C161SB-WH/BK
P162JPW-OR
JSGND3-BR
C163PLS-BL/WH
P162JPW-OR
JSGND2-BR
C164PES-RD/WH
C165TRS-WH/RD
P162JPW-OR
JSGND1-BR
ESTOP PWR-RD/BK
ESTOP RET-BK
JIB DN-GN/BK
GND13-BR
JIB UP-GN
PLAT LVL DN-OR/BK
GND6-BR
PLAT LVL UP-OR
PLAT ROT R-GN/BK
GND16-BR
PLAT ROT L-GN
C
MULTI FUNCTION VLV RECOVERY SIGNAL
AUX HYD
CONTACTOR
12 WAY
S56PRV-RD
P54ENG-BK/WH
P2-02 DCON ECU PWR
10
SERV. OR OPER. REC. 9
P22
OPER. REC. 11
JSGND4-BR
JSGND1-BR
P162JPW-OR
C165TRS-WH/RD
P162JPW-OR
C164PES-RD/WH
C163PLS-BL/WH
C161SB-WH/BK
C160JPL-WH/RD
C159STC-BL/WH
C159STC-BL/WH
P162JPW-OR
P162JPW-OR
JSGND2-BR
JSGND3-BR
GND12-BR
ALARM+ RD/BK
AUXILIARY HYD RECOVERY SIGNAL
AUX HYD PUMP
8
12
R
STARTER RELAY
6
21
NC
13
NO
Q
STARTER
2
P58LS RD/BK
P54ENG-BK/WH
P53LS-WH/BK
P2-01 DCON ECU GND
SERV. OR
OPER. REC.
13
P7-GR/WH 12
P11
TCON MODE 14
ALARM+ RD/BK
ESTOP PWR-RD/BK
ENGINE CAN BUS
TO ENGINE D2.2
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
20
19
PLAT ROT R-GR/BK
PLAT ROT L-GR
18
GND16-BR
17
JIB DN-GR/BK
JIB UP-GR
GND13-BR
GND12-BR
ESTOP RET-BK
PLAT LVL DN-OR/BK
PLAT LVL UP-OR
GND6-BR
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
P20
A
LSP1AO
> 5 DEG
J43
4
22
21
WH
BK
BR
RD
10 12
14
654321
LSS2AO
RAISED OPER
J51
D82CAN+ -YL
7 11
S12SBL-BL/WH
LSS1AO
5 DEG
J50
D81CAN- -GR
3
22 21
NC
14 13
WHT NO
654321
LST1O
DRV ENABLE
J48
D81CAN- -GR
4321
WH
BK
BR
RD
NORMAL SWITCH POSITION
SHOWN FOR: LSJ1EO
P
LSS1RO
SEC RET OPER
J49
J114
21
5 611 10
S59SBE-GR/WH
P53LS-WH/BK
P58LS-RD/BK
SJ1-WH/RD
87a
WH
BK
BR
RD
P21DCN-WH
18/19
CABLE
S73SLD-GR/BK
B1ENG (12 VOLT)
LST1O
DRV ENABLE
J48
P53LS-WH/BK
4 7
C64LS-OR/BK
C124SBL RD/WH
SJ1-WH/RD
FST1S
LOW FUEL FS
S132LDS-BL/WH
3
C64LS-OR/RD
C124SBL RD/WH
P23PCON-BK
S56PRV-RD
LSS2AS
RAISED
SAFETY
J47
GNDDCN-BR
1 12 2
TO
MICRO
TO
MICRO
OR
BL
WH
BK
BR
RD
C46HN-WH
8
TO
MICRO
OR
BL
WH
BK
BR
RD
S56PRV-RD
J20B
3 12 WAY 9
LSS1RS
3' EXT
J46
GND-BR
2
C70PBR-BL/WH
C64LS-OR/BK
OPTIONAL RELAYS
LOCATED ON ENGINE HARNESS
OR
BL
WH
BK
BR
RD
85
PLD
OR
BL
WH
BK
BR
RD
C47OUT-WH/BK
1
OR/RD
BK/RD
OR
BL/RD
86
J20A
4 WAY
C64LS-OR/BK
C71PBE-BL/BK
OPTIONAL SWING
GATE WIRING
WH
BK
BR
RD
30
RED ALARM
LED
LSP1RO
3' EXTENDED
J45
87
P21DCN-WH
P15
ALARM GND 16
ALARM PWR 15
PCON POWER
WH
BK
BR
RD
C117FB-RD
85
GND-BR
BL/WH
BK BK
RED
86
30
WH
BK
BR
RD
TO FLASHING BEACON
87a
WH
BK
BR
RD
P52PCON-WH
LSP1EO
3' FROM FULLY
EXTENDED
J44
BOOM HARN
S12SBL-BL/WH
J11 BLACK 23 PIN
WH
WH/RD
WH/BK
TCON
WH
WH/RD
WH/BK
P56PRV-RD/WH
P21DCN-WH
P53LS-WH/BK
P53LS-WH/BK
TCON MODE
S59SBE-GR/WH
OUT PWR ENABLE
GNDDCN-BR
PWR TO TCON ESTOP
POWER FET POWER FET
R211IGN-WH
87
LIMIT SWITCH HARN
RD
RD/WH
RD/BK
2
J12 BLACK 35 PIN
SJ1-WH/RD
6 J55
PCON POWER
P6R1
P54ENG-BK/WH
P11
BK/WH
P7R
C123PBD RD/BK
TO MICRO
P109PBTS-GR/WH
BOOM HARN
SNSR GND-BR
J21 BLACK 23 PIN
(P15)+(ECU POWER)
OR/BK
TO WORK LIGHTS
R48LPS-RD/WH
P15
P109PBTS-GR/WH
P1-23 TET ESTOP RET
P1-22 DIAG/TETHER PWR
P1-21 DIAG/TETHER GND
P1-20 TETHER FUNC ENBL
P1-19 RS232 GND
P1-18 CAN HIGH
P1-17 CAN LOW
P1-16 SPARE
P1-15 TET ESTOP PWR
P1-14 LOAD SENSR INPUT
P1-13 BOOT
ECU POWER
C123PBD RD/BK
RS232 RXD
P1-12 RS232 TXD
P1-11
P1-10 CAN SHIELD
P15
18/19
CABLE
U30
P1-09 FLASHING BEACON
P1-08 WORK LT
P_7
P1-07 P_22
P1-06
P1-05 PWR-PCON ESTOP
P1-04 OUT PWR ENBL
P1-03 HORN RELAY COIL
P1-02 PCON POWER
U20
P3 - TO MICRO
SNSR GND-BR
D82CAN+ -YL
D81CAN- -GR
S132LDS-BL/WH
C117FB-RD
P56PRV-RD/WH
S56PRV-RD
P23PCON-BK
C47OUT-WH/BK
C46HN-WH
P1-01 PCON GND
P1-23 PWR-PCON ESTOP
P1-22
P1-21
P1-20
P1-19
3
BK/WH
B
SERVICE OR RECOVERY MODE
OR/BK
RD
RD/WH
RD/BK
D82CAN+ -YL
A
J17
POWER FET
D81CAN- -GR
3
P7R
LSS2AS
RAISED
SAFETY
J47
J35-LIMIT SW HARN
P1-18 CAN+
P1-17 CAN-
P1-16 HRN RLY CNTRL
P1-15 OUT PWR ENBL
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07 P22
P1-06
P1-05
P1-04 P7
P1-03
P1-02 PCON PWR
P1-01 PCON GND
BTS650 U21
Vbb
OUT
IN
IS
TCON MODE
P_7
LSS1RS
3' EXT
J46
J34-LIMIT SW HARN
P23PCON-BK
P1-23 SAFE PL TILT PWR
P1-22 SAFE PL TILT GND
P1-21 PL TILT SNSR PWR
P1-20 PL TILT SNSR
P1-19 PL TILT SNSR GND
P1-18 PL LVL CYL EXT
P1-17 FOOT SW RTN
P1-16 FOOT SW PWR
PIN CKT #
2
RS232_RXD
3
RS232_TXD
5
RS232_GND
P_22
LSP1RO
3' EXTENDED
J45
J33-BOOM HARN
D82CAN+ -YL
D81CAN- -GR
C47OUT-WHT/BLK
C46HN-WH
P56PRV-RD/WH
S56PRV-RD
P52PCON-WH
GNDPCON-BR
P87PTS-RD
PTSRET-BR
P85PTS-GR
C84TAY-GR/BK
PLATRET-BR
S14PLU-OR
C56FTS-RD
P56FTS-RD
C88PTS-RD/BK
P1-14 LOAD SNSR PWR
P1-15 SAFE PL TILT OUT
P1-13 LOAD SNSR SIG
P1-12 LOAD SNSR GND
P1-11 PROX KILL CMD
P1-10 PROX KILL GND
P1-09
P1-08 PROP VLV1_B
P1-07 PROP VLV1_A
P1-06 PROP VLV2_B
P1-05 PROP VLV2_A
P1-04 ON/OFF VLV3_B
P1-03 ON/OFF VLV3_A
P1-02
P1-01 VLV RTN
ON CIRCUIT BOARD
DB9 CONNECTOR
1
POWER FET
S132LDS-BL/WH
4
1
-
C46HN-WH
2
P23PCON-BK
V
-
C47OUT-WH/BK
1
2
BL
J119
1
BL/BK
P23PCON-BK
2
W
OFF
GROUND
2
PLAT
BL
P56PRV-RD/WH
S56PRV-RD
2
2
BL/BK
S56PRV-RD
1
GNDPCON-BR
3
+
-
SWING GATE
INTERLOCK
2
4
OFF
GROUND
1
PLAT
SNSR GND-BR
P52PCON-WH
Z
1
GR/WH
GNDPCON-BR
1
P52PCON-WH
GNDPCON-BR
C56PTS-RD
C23PTS-WH
J31 23 PIN
3
D
GR/WH
WH
BK
BR
RD
+
POWER FET
10 DEG
SAFETY CUTOUTS
+
-
0-20DEG Y AXIS
2
4
OFF
GROUND
2
PLAT
SNSR GND-BR
POWER FET
10 DEG -
+
C56FTS-RD
R56FTS-RD
RD
OR
GR/YL
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
C44JD-GR/BK
C43JU-GR
C18PRR-GR/BK
C17PRL-GR
VLVRET-BRN
AXLE NOT EXT PWR
RS232 GND
CAN +
CAN -
BTS621 U22
Vbb
IN1 OUT 1
IN2 OUT 2
ST
GND
Y
1
TCON
ESTOP
GR/BK
BK
RD
PLAT LEVEL DN (J81)
PLAT LEVEL UP (J80)
JIB DOWN (J79)
JIB UP (J78)
PLAT ROT CW (J76)
PLAT ROT CCW (J77)
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
AXLE NOT EXT SIG
5
3
E
GR
WH
BK
BR
RD
WH
BK
BR
RD
WH
BK
BR
RD
R90PXS-RD/BK
C90PXS-RD/BK
D82CAN+ -YL
D81CAN- -GR
P1-16
P1-15
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
AXLE NOT RET RTN
DIGIN AXLE RET GND
P12
P_7R
P_6R1
DCON ECU PWR
DCON ECU GND
LED/TOGGLE SWITCH INTERFACE PCB
X
OFF
GROUND
2
PLAT
18/19
CABLE
BK
RD
WH
BK
BR
RD
S56PRV(B)-RD
S56PRV-RD
V122AXO-GN/WH
S56PRV(A)-RD
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
P1-02
P1-01
LF STEER LEFT
LF STEER RIGHT
RF STEER LEFT
STEER SNSR PWR
STEER SNSR GND
RF STEER RIGHT
LR STEER LEFT
LR STEER RIGHT
BRAKE
VALVE RTN2
LR STEER SNSR
RF STEER SNSR
LR STEER SNSR
RR STEER SNSR
RR STEER LEFT
RR STEER RIGHT
AUX REVERSE
AUX FORWARD
OSCIL;ATE STOWED
MOTOR SPEED
BL/WH
GR/BK
WH
BK
BR
RD
S56PRV(A)-RD
S56PRV-RD
V121AXO-GN
S56PRV(B)-RD
P2-23
P2-22
P2-21
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
P2-13
P2-12
P2-11
P2-10
P2-09
P2-08
P2-07
P2-06
P2-05
P2-04
P2-03
VALVE RTN1
J24 20PIN
4
OFF
GR
21
NC
14 13
NO
TIER IV ENG OPT
GBOX HARN
1
OFF
GROUND
2
PLAT
TCON
ESTOP
70 TO 35 DEG Y-AXIS
V122AXO-GR/WH
V121AXO-GR
WH
BK
BR
RD
S56PRV-RD
S56PRV-RD
P53LS-RD
P21DCN-WH
GND-DCN-BR
V37LFS-BL/BK
V36LFS-BL
V37RFS-BL/BK
P109ANG-GR/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
V29MS-RD/WH
P2-02
A
B
C
J223
MOLEX
8PIN
U
1
SAFETY CUTOUTS
+ 80 DEG
+ 80 DEG
BK
BL
RD
BK
BL
RD
BK
BL
RD
BK
BL
RD
22
(TSx)
RUN
SERV BYPASS
2
RECOVERY
BL/WH
C
LSP1EO
3' FROM FULLY
EXTENDED
J44
Y56 OSCILLATE
LEFT (J85)
Y57 OSCILLATE
RIGHT (J86)
Y62-LF STEER LEFT (J98)
Y61-LF STEER RIGHT (J97)
Y60-RF STEER LEFT (J96)
Y59-RF STEER RIGHT (J95)
Y58-LR STEER LEFT (J94)
Y57-LR STEER RIGHT (J93)
Y56-RR STEER LEFT (J92)
Y55-RR STEER RIGHT (J91)
S14-LF STEER RIGHT
S13-RF STEER RIGHT
S12-LR STEER RIGHT
S11-RR STEER RIGHT SNSR
2 1
SPARE
SERVICE/BYPASS SWITCH WIRING
CHANGED AT SERIAL NUMBER Z8015-5654
O
CAN LOW (-) P1-08 D227CAN(-) GR
CAN HIGH (+) P1-07 D228CAN(+) YL
C226TEL-BL
FOOTSW (FS1)
#1
1
OFF
GROUND
2
PLAT
N
S56PRV-RD
P2-01
SERVICE
HORN (BN5)
U
M
P1-06
VLVRET-BR
CAN GATEWAY
& TCON LCD
RUN
SERV BYPASS
2
RECOVERY
L
P1-05
Y2-BRAKE RELEASE (J106)
TIER IV CAN GATEWAY
& TCON LCD
ADDED AT SERIAL NUMBER
Z8014-4987
K
REMOTE DISABLE
FOOTSWITCH STATUS
21
NC
STEER MODE
SELECT
(TS22)
J
KEY SWITCH PWR P1-04 P23PCON-BK
IGNITION STATUS P1-03 C21TEL-WH
GROUND P1-02 GND-BR
RD
WH/BK
I
SYS_POWER P1-01 B1BAT-RD
Y27-TWO SPEED MOTOR STROKE (J87)
1
120Ω
FOOTSWITCH
SPARE-WH
ON CIRCUIT BOARD
DB9 CONNECTOR
DRIVE
SPEED
(TS5)
STR MODE R-OR/BK
2
WH
ENGINE
SPEED
(TS4)
STR MODE L-OR
2
DCON GND BK
B
DRV SPEED-RD/WH
1
P7R
BK
A
B
19
1
WH
A
20
2
GR
AXLE
EXT/RET
(TS23)
GND2-BR
2
YL
CAN LOW
ENG SPEED-BK/RD
1
CAN HIGH
18
1
YL
GR
NOT USED
P53LS-WH/BK
J17-DRIVE CHASSIS HARN
B
17
P21DCN-WH
J18-DRIVE CHASSIS HARN
A
B
SPARE-WH
S56PRV-RD
GNDDCN-BR
A
STR MODE R-OR/BK
S56PRV-RD
GNDDCN-BR
J16-DRIVE CHASSIS HARN
DRIVE
ENABLE
(TS15)
AXLE EXT-GR/WH
D81CAN- -GR
15
D82CAN+ -YL
P6
16
SLIP RING
D82CAN+ -YL
D81CAN- -GR
P6
NOT USED
J23 10PIN
NOT USED
LSJ1EO
PLATFORM LEVEL
CYL FULLY EXT SWITCH
(STOWED POS)
13
NO
AXLE RET-GR
P21DCN-WH
14
6
13
P53LS-WH/BK
14 13
NO
P7R
14
AXLE LS
OSCILLATE
LIMIT SWITCH
(STOWED POS)
21
NC
P7R
STR MODE L-OR
AXLE RS
OSCILLATE
LIMIT SWITCH
(STOWED POS)
LSA2OS
2
ENGINE
START
(TS2)
DRV SPEED-RD/WH
LSA1OS
OVERLOAD
LIMIT SW
LS18A
LS18
(SHOWN IN
OVERLOADED
CONDITION)
22
22
11
NO
J84
74HC08
12
P22
AXLE EXT-GR/WH
NO
LSP1 PROX
PROXIMITY
KILL SWITCH
OPTIONAL
21
2 74HC08
ENG SPEED-BK/RD
B C
NO
PLATFORM
TILT SENSOR
ASSEMBLY
1
9
A
NO
OVERLOAD
LIMIT SW
LS18A
LS18
4 3 21
10
B C
LSP1 PROX
KILL SWITCH
CHANGED AT
S/N Z8015-5514
21
NC
14 13
1. PLAT SNSR GND
2. TILT SNSR SIG OUT
3. TILT SNSR PWR
4. TILT SW GND
5. PWR TO TILT SW
6. OUTPUT FROM TILT SW
1
GND1-BR
A
NC
14 13
22
PCON MANIFOLD
8
B C
22 21
NORMAL SWITCH POSITION
SHOWN FOR: LSA1OS
LSA2OS
PROX KILL
SWING GATE
LSP1 PROX
J82
PROXIMITY
KILL SWITCH 2 1
OPTIONAL
J22 WHITE 23 PIN
NOT USED
NO
PIN CKT #
2
RS232_RXD
3
RS232_TXD
5
RS232_GND
AXLE RET-GR
NC
14 13
1
5
6
A
J110
4321
21
4 3 2 1
4
7
B C
J109
J105
WH
DRV ENBL-BL/WH
A
J108
22 21
NC
14 13
22
J82
3
ECU
5
43 2 1
4 3 21
2
1
ENG START-BK
P7
SLP_MODE
START ASST-BK/WH
4
START
ASSIST
(TS6)
DRV ENBL-BL/WH
ES0508 Rev K
3
J104
1
5
AUXILIARY
PUMP
(TS1)
ENG START-BK
Electrical Schematic
START ASST-BK/WH
from S/N Z8013-4592 to Z8015-5653
4
6
H
-
Genie Z-80
AUX PUMP-RD
P6
GENERATOR
ON/OFF
(TS17)
GEN ON/OFF-GR/WH
10
DRIVE CHASSIS
HARNESS
1
13
J107
DRIVE CHASSIS
HARNESS
DRIVE & STEERING
JOYSTICK (JC3)
2
7
SEC BOOM UP/DWN
JOYSTICK (JC5)
HORN RET-GR
11
J32 23 PIN
PCON
E-STOP (P2)
PRI BOOM EXT/RET
JOYSTICK (JC2)
G
-
2
HORN PWR-RD
12
DEUTZ TD2011L04i ENGINE SHOWN
JIB
BOOM UP/DWN &
TURNTABLE ROTATE
JOYSTICK (JC1)
AUX PUMP-RD
9
DCON EN7
PLATFORM PLATFORM
ROTATE
LEVEL
F
+
PCON
ALARM
E
GEN ON/OFF-GR/WH
8
D
HORN RTN-GR
4
C
HORN PWR-RD
3
B
+
A
Y
Z
LOCKOUT VALVE #1 SIG
PRI BOOM LENGTH 100' STATUS
TCON MEMBRANE PANEL
PRI BOOM DOWN STATUS
AUXILIARY HYD RECOVERY SIGNAL
PWR TO TCON ESTOP
P_22
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
TO MICRO
P_30
P_22R
TO
MICRO
((~SM)+(AH))(OE)
(OE)
4
6
4
~SLP MODE (~SM)
(~SM)+(AH)
5
5 AUX HYD (AH)
74HC08
2
3
FUNC ENABLE (FE)
1
74HC08
TCON MODE(TM)
P7R
P_7
P10
TO
MICRO
P6R1
P9A
TO
TO
MICRO MICRO
Y56 OSCILLATE
LEFT (J85)
Y57 OSCILLATE
RIGHT (J86)
P6R1
WH/BK
1
2
2
1
1
2
2
S56PRV-RD
S56PRV-RD
GND DCN-BR
GNDDCN-BR
P21DCN-WH
P21DCN-WH
P53LS-WH/BK
P53LS-WH/BK
PRI BOOM ANG SENSOR
WHT
21
22 21
NC
14 13
NO
WHT
4321
22 21
NC
14 13
NO
654321
12
11
NC
22 21
NC
13 14
NO
YEL
11
NC
22 21
NC
13 14
NO
PUR
12
654321
22
ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION
21
NC
14 13
ORN NO
21
14 13
NO
24 23
22 21
NC
14 13
BLU NO
RED
NO
4321
21
NC
14 13
GRN NO
22
4321
4321
STARTER
21
NC
14 13
BRN NO
22
B2
B1
ENGINE
BLOCK
AUX.
PUMP
BAT.
+
BAT.
-
STA.
REGULATOR IND.
ALTERNATOR
EXCT.
D1
1
2
3
A B C D
H1
30
87 87a
85
OTS1N.O.
CR17
30 OIL
87 87a COOLER
RELAY
D5
C25PSR-WH/BK
V126SBLD-WH/BK
V126SBLD-WH/BK
R21IGN-WH
J120
FAN
D8
DUETZ TD2011L04i ENGINE SHOWN
C27AUX-RD
P126SBLD-WH/BK
B1ENG-RD
C21IGN-WH
30 86 CR28
ENG ALT
87a 87 85 RELAY
P P P
1 30
87a 3
87
4
2 86 85 5
D7
P
D3
TURNTABLE_ROTATE_VLV
P4-04
PRI_EXTEND_VLV
PRI_RET_VALVE
P4-08
P4-09
P4-10
C02PBD-RD/BK
C07PBE-BK
C08PBR-BK/WH
SEC_RET_VLV
P4-20
C73SBR-BL/RD
C04TRL-WH
C05TRR-WH/BK
VALVE_RTN7
P4-27
SEC BOOM DOWN SEQ #2 VALVE
P4-34
P126SBLD-WH/BK
P4-35
AUX_RELAY
SEC BOOM EXT SEQ #1 VLV
P4-32
TO
MICRO
P4-33
TO PLD
TO PLD
TO
TO
TO
MICRO MICRO MICRO
P125SBLE-WH/RD
P4-31
TO PLD
TO PLD
P7R
P4-30
TO MICRO
TO
MICRO
P4-29
VALVE_RTN6
ROTATE_CCW_VLV
P4-28
ROTATE_CW_VLV
P4-26
MULTI_FUNCT_VLV
P4-25
P4-24
P4-23
P4-22
C72SBE-BL/WH P4-21
SEC_EXT_VLV
SEC_UP_VLV
P4-19
C10SBU-BL
P4-18
LSS2AS MONITOR INPUT
SPARE
P4-17
S10SLE-BL
LSS1RS MONITOR INPUT
SPARE
P4-15
VALVE_RTN5
DRIVE LIGHTS RELAY
P4-16
P4-14
VLVRET5-BR
S73SLD-GR/BK
P4-12
P4-13
C11SBD-BL/BK
R49LP - WT/BK
SEC_DWN_VLV
PRI_DOWN_VLV
P4-07
C01PBU-RD
P4-11
SEC. BOOM F.C.
PRI_UP_VLV
P4-06
C12SBFC-BL/WH
P4-05
BOOM_EXT/RET_VLV
P4-03
C06TRF-WH/RD
C27AUX-RD
V125SBLE-WH/RD
P125SBLE-WH/RD
P126SBLD-WH/BK
C27AUX-RD
S73SLD-GR/BK
VALVE RTN6
NEUTRAL WH
VALVE RTN6
RD/12VDC
VALVE RTN7
NEUTRAL WH
VALVE RTN7
P126SBLD-WH/BK
V125SBLE-WH/RD
P34 J34
S10SLE-BL
1
P125SBLE-WH/RD
2
P126SBLD-WH/BK
3
V125SBLE-WH/RD
4
V126SBLD-WH/BK
S10SLE-BL
P125SBLE-WH/RD
C05TRR WH/BK
LINE BK
C04TRL-WH
WH
C10SBU-BL
C73SBR-BL/RD
C72SBE-BL/WH
NC
C10SBU-BL
C73SBR-BL/RD
C72SBE-BL/WT
P125SBLE-WH/RD
TO
MICRO
TO DRIVELAMPS
P125SBLE-WH/RD
P126SBLD-WH/BK
SEC EXT VLV (J65)
S73SLD-GR/BK
S10SLE-BL
SEC UP VLV (J67)
S73SLD-GR/BK
S10SLE-BL
TO
MICRO
SEC RET VLV (J66)
C26TSR-WH/RD
TO
MICRO
12 VOLT
FIELD BK/WH
TO
MICRO
SEC DWN VLV (J68)
P116HYD-OR
TO PLD
P_30
R49LP - WT/BK
BK
BK
15A- 120VAC GENERATOR
12.5A- 220VAC GENERATOR
C11SBD-BL/BK
BK
TO
MICRO
VLVRET5-BR
FIELD BK/WH
C08PBR-BK/WH
GN
C07PBE-BK
BR GND
PRI EXT VLV (J62)
AUTO
RESET CB
J9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
PRI BOOM LENGTH 3' STATUS
TT ROT CW VLV (J70)
86
LINE BK
PRI RET VLV (J63)
BR
C02PBD-RD/BK
GND BR
PRI DWN VLV (J60)
WH
OPTIONAL 120VAC W/REGULATOR
C01PBU-RD
BR
4
X
TT ROT CCW VLV (J71)
B
87
C09PERF-BK/RD
TURNTABLE
TILT SENSOR
C12SBFC-BLU/WT
6
PRI UP VLV (J59)
5
MANIFOLD HARN
BOOM_UP/DOWN_VLV
DUETZ TD2011L04i ENGINE SHOWN
SEC. BM F.C. (J64)
RET85TTSR-BR
TO
MICRO
C06TRF-WH/RD
P85TTSR-GR
J14 WHITE 35 PIN
C09PERF-BK/RD
2 86 85 5
4
PRI BM EXT/RET F.C. (J61)
C45GEN GN/WH
3
3
VALVE_RTN4
J31-TILT SNSR
P4-02
P31-ENG HARN
P4-01
TCON
VLVRET4-BR
PERKINS 804D ENGINE- SEE ENGINE OPTION PAGE
CONTINENTAL TME27 ENGINE- SEE ENGINE OPTION PAGE
DEUTZ TD2.9 SEE ENGINE OPTION PAGE
PERKINS 404TF SEE ENGINE OPTION PAGE
C03PBF-RD/WH
P_11
C03PBF-RD/WH
87a
W
TT ROT CW/CCW F.C. (J69)
RD-HOLD
1 30
VLVRET4-BR
TO PLD
P10
PRI BM UP/DN F.C. (J58)
C83TAX-GR/WH
RET85TTSR-BR
V125SBLE-WH/RD
P85TTSR-GR
+
+
-
(EXT ENABLE) SEC BM EXT SEQ #1
C84TAY-GR/BK
2
V126SBLD-WH/BK
J10
V
(DWN ENABLE) SEC BM DN SEQ #2
C83TAX-GR/WH
1
VOLTAGE
7
REGULATOR
C84TAY-GR/BK
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
P22R
C26TSR-WT/RD
74HC08 13
C25PSR-WT/BK
AC GENERATOR
P1-23 VALVE_RTN3
P1-22
P1-21 TT_TILT_Y_AXIS
P1-20 TT_TILT_X_AXIS
P1-19
P1-18 ALTERNATOR RPM
P1-17 AC GENERATOR
P1-16 VALVE RTN_2
P1-15 TT_TILT_SNSR_PWR
P1-14 TT_TILT_SNSR_GND
P1-13 OIL/WATER_TEMP
TO HORN BUTTON
(P15)+(ECU POWER)
P22R
C21IGN-WH
B1ENG-RD
EDC REV
P1-12 OIL_PRESSURE
P1-11
P1-10 EDC FWD
TO
MICRO
OIL TEMP SENDER
J57
CR15 86
ST AID
RELAY 85
30A
R21IGN-WH
C41RPM-OR/BK
VLVRET2-BR
C26TSR-WH/RD
C25PSR-WH/BK
C31EDC-WH/BK
P1-09 STARTER RELAY
P_9B
OIL PRESSURE
D2
C30EDC-WH
P1-08
P1-07 SERVICE HRN
P_7
P7R
U95
BAT GND-BR
C
U
FUEL SOLENOID
P34SA-BK/WH
R116HYD-OR
WH-PULL IN
C21IGN-WH
C229TEL-BL/BK
P116HYD-OR
NOTE: FOR ACTIVE LOW
TELEMATICS SYSTEMS
C229TEL IS CONNECTED TO
B2BAT+ STUD ON RELAY BLOCK
(ACTIVE HIGH SHOWN)
C116HYD-WH
C45GEN-GR/WH
BAT GND-BR
S-500
86 CR5
HORN
87a 87 85 RELAY
P32-GEN HARN
B1BAT RD
HYDRAULIC
OIL COOLER FAN
AUX+
30
BAT GND-BR
C34SA-BK/WH
J32-ENG HARN
COOLER
RELAY
GND-
TO
MICRO
TEMP SW
A
R34SA-BK/WH
BAT+
GLOW PLUG
P34SA-BK/WH
VLVRET-BR
F7 OIL COOLER
F20 HI/LO RPM
F22 GLOW PLUG
F23 ENG/ST/ALT
GLOW PLUG
RELAY
P116HYD-OR
C31EDC-WH/BK
C226TEL-BL
C30EDC-WH
GND04-BR
P128 J128
S73SLD-GR/BK
BATGND(A) - BK
TROMBETTA
TIME DELAY
MOM N.O.
P1-06 REV
P6R1
12
GND04-BR
4321
TO
MICRO
BK
87a
P1-05 FWD
TO
MICRO
WH-PULL IN
85
P1-04 START ASSIST
(~SM)+(AH)
T
DUAL COIL
EDC
22
30
CB7
15A
21
NC
14 13
BRN NO
CR1
30 86
STARTER
87a 87 85
RELAY
86
RD-HOLD
6 AMP
ENGINE HARN
RD
P53LS-WH/BK
TO MICRO
WH
C124SBL RD/WH
C68PBD-RD
J13 WHITE 23 PIN
HOLD
CB9
CR80
TELEMATICS
RELAY
TO
MICRO
PULL IN
S59SBE-GR/WH
J224 GREY 8 PIN
TELEMATICS
5V 12V
GND
TROMBETTA
HI/LO SPEED
SOLENOID
P58LS-RD/BK
74HC08
SERVICE
HORN
ENGINE CAN
BUS TO CAN
GATEWAY
14
VLVRET2-BR
C64LS-OR/BK
TELEMATICS OPTION
ADDED AT SERIAL NUMBER
Z8013-4765
P_7
P46HRN(A)-WH
C73SBR-BL/RD
C66DREN-BL
U32
10
BAT GND-BR
S56PRV-RD
POWER HARN
(TM)(FE)
P1-03 IGN/FUEL
TCON MODE
P_7
C33STR-BK
J15 BLACK 4 PIN
(~SM)+(AH)
C41RPM-OR/BK
GNDDCN-BR
P_6R2
C107AF-RD
P_22
OUT PWR ENABLE (OE)
C46HRN-WH
TCON
74HC08
C34SA-BK/WH
P_11
((~SM)+(AH))(P_7) 8
9
P1-02 THROTTLE
P11
P22R
C21IGN-WH
P11
BTS650
Vbb
OUT
IN
IS
P1-01 VALVE RTN#1
PCON POWER
C35RPM-BK/RD
P6R1
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
((~SM)+(AH))(P_22) 11
C27AUX-RD
BOOM STOWED
P7R
C35RPM-BK/RD
BTS650
Vbb
OUT
IN
IS
P1-04 BATECU-PWR
J127 LOADSENSE LED
C33STR-BK
P9A
P6R1
(~SM)+(AH)
(BM STOWED)
P1-03 BATECU GND
P_22
B1BAT-RD
PCON POWER
BTS650
Vbb
OUT
IN
IS
GND-BR
P10
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
P_7
P_6R2
30 A
B1ENG-RD
P_1
OUT PWR ENABLE
P1-02 SYS BAT GND
P_30
TO HORN BUTTON
GND-BR
TO
MICRO
CB
TO HORN BUTTON
20A
(P15)+(ECU POWER)
P1-01 SYS_BAT_PWR
(P15)+(ECU POWER)
B1BAT-RD
BOOM UP/DWN FC RECOVERY SIGNAL
20 A
F23
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
B1BAT-RD
P10
P35RPM-BK/RD
BOOM DWN RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
F22
TO HORN BUTTON
P_6R2
G-P MODE GR/BK
BOOM DWN RECOVERY SIGNAL
60 A
F20
P_7
AUX MAIN
P7R
B2BAT-RD
P7R
10
RD
74HC08
20 A
TCON MODE
P_7
RD
2
8
PR1
21
NC
14 13
GRN NO
F7
((~SM)+(AH))(BM STOWED)
9
P33STR-BK
RD
Vbb BTS621
IN1
OUT 1
IN2
ST OUT 2
GND
RD
C77SBU-WH
WH/BK
BL/WH BL/WH
BOOM RET RECOVERY SIGNAL
BAT GND-BR
22
C64LS-OR/BK
C68PBD-RD
C64LS-OR/BK
C77SBU-WH
V125SBLE-WH/RD
P125SBLE-WH/RD
C67SBD-BL
P2-35 VLV RET
P9A
P6R1
TO MICRO
TO PLD
1
RD
4321
WH
BK
BR
RD
C64LS-OR/BK
C77SBU-WH
V125SBLE-WH/RD
P125SBLE-WH/RD
C64LS-OR/BK
C67SBD-BL
C64LS-OR/BK
C73SBR-BL/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
C64LS-OR/BK
P2-34 P_30
P2-33 SEC ANG INPUT
P2-32 PRI ANG INPUT
P2-31 BOOM STOWED
P2-30 LSB14AO
P2-29 LSB13AO
P2-28 DIGITAL IN
TO PLD
TO PLD
B
P23PCON-BK
OUT PWR ENABLE
S
HORN
RELAY
ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION
4321
WH
BK
BR
RD
C64LS-OR/BK
C67SBD-BL
C64LS-OR/BK
C73SBR-BL/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
C66DREN-BL
C64LS-OR/BK
S12SBL-BL/WH
C123PBD RD/BK
TO PLD
P2-27 PRESSURE GA
P2-26 SNSR PWR
P2-25 SNSR GND
P2-24 P2 SEQ
P2-23 P1 SEQ
P2-22 LSS2AO
P2-21 LSS1AO
P2-20 LSP1EO
P2-19 LSP1RO
P2-18 LSB2RO
.
P2-17 LSP1AO
P2-16 LSS1RO
P2-15 LST10
P2-14 FST1S
P2-13 OPER SW PWR
C47OUT WH/BK
TCON MODE
P223-08 DIGITAL IN 2
P223-07 DIGITAL IN 1
P223-05 MACHINE CAN HIGH
P223-06 MACHINE CAN LOW
P_22
START BAT
22 21
NC
14 13
BLU NO
LSP1AO
> 5 DEG
J43
14 13
NO
24 23
RED NO
LSS2AO
RAISED OPER
J51
21
WH
BK
BR
RD
D82CAN+ -YL
WH
BK
BR
RD
NC
14 13
ORN NO
LSS1AO
5 DEG
J50
22
LSS1RO
SEC RET OPER
J49
WH
BK
BR
RD
C64LS-OR/BK
C65LOFL-BL/WH
P58LS-RD/BK
S59SBE-GR/WH
C124SBL RD/WH
P109PBS-GR/WH
SNSR GND-BR
P_14
P2-12 P_18
P2-11
P2-10 P_12
P2-09 P_11
P2-08 P_10
U32
U31
U30
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
MLT FNC VLV O
AUX HYD O
BM DWN ST I
BM 3' I
BM 100' I
PRI LO#1 O
BL/BK
C47OUT GN/BK
S1 PBU-OR
P_7 PLAT-GN/WH
C47OUT WH/BK
P_15-OR/BK
ALM PWR-RD
D82CAN+ -YL
D81CAN- -GR
P223-03 ENGINE CAN HIGH
P223-04 ENGINE CAN LOW
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
ALTERNATOR
11
NC
21
NC
13 14
NO
PUR
C64LS-OR/BK
SJ1-WH/RD
P53LS-WH/BK
P58LS-RD/BK
S59SBE-GR/WH
C77SBU-WH
C67SBD-BL
C71PBE-BL/BK
C70PBR-BL/WH
C64LS-OR/BK
C68PBD-RD
C73SBR-BL/RD
C66DREN-BL
C65LOF-BL/WH
C64LS-OR/BK
P54ENG-BK/WH
P53LS-WH/BK
P53LS-WH/BK
S12SBL-BL/WH
P2-07 P_9B
3
TCON ESTOP-BL/WH 2
TETHER ESTOP-BL/RD
ECU POWER 4
P23PCON-BK
C47OUT WH/BK
P53LS-BK/WH
S56PRV-RD/BK
SRV REC-WH
P56PRV-RD
OR/BK
GR/WH
OR
J228-4
D228CAN+ YL
D227CAN- GR
J25
J28
J26
J27
P223-01 GROUND
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
P223-02 CAN SHIELD
PWR TO TCON ESTOP
AUX HYD
ELECTRONICS
BATTERY
22
4321
WH
BK
BR
RD
12
C65LOFL-BL/WH
S59SBE-GR/WH
P53LS-WH/BK
P58LS-RD/BK
SJ1-WH/RD
SJ1-WH/RD
P53LS-WH/BK
P58LS RD/BK
P54ENG-BK/WH
P2-06 P_9A
P2-05 P_7R
P2-04 P_6R2
P2-03 P_6R1
P2-02 DCON ECU PWR
6
OUTPUT PWR ENABLE
RD
RD/WH
J228-2
J228-3
ENGINE CAN
BUS TO
TELEMATICS
ALM-GND-BR
MACHINE CAN BUS
TO J152
ENGINE CAN BUS
TO ENGINE D2.2
J228-1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW-OR
JSGND4-BR
C161SB-WH/BK
P162JPW-OR
JSGND3-BR
C163PLS-BL/WH
P162JPW-OR
JSGND2-BR
C164PES-RD/WH
C165TRS-WH/RD
P162JPW-OR
JSGND1-BR
ESTOP PWR-RD/BK
ESTOP RET-BK
JIB DN-GN/BK
GND13-BR
JIB UP-GN
PLAT LVL DN-OR/BK
GND6-BR
PLAT LVL UP-OR
C
MULTI FUNCTION VLV RECOVERY SIGNAL
AUX HYD
CONTACTOR
11
NC
21
NC
13 14
NO
YEL
4321
WH
BK
BR
RD
22
S10SLE-BL
S59SBE-GR/WH
P53LS-WH/BK
P58LS-RD/BK
SJ1-WH/RD
C68PBD-RD
C73SBR-BL/RD
C66DREN-BL
C65LOF-BL/WH
C64LS-OR/BK
P54ENG-BK/WH
P54ENG-BK/WH
S12SBL-BL/WH
P53LS-WH/BK
S56PRV-RD
P54ENG-BK/WH
P53LS-WH/BK
7
P6R1
PCON MODE 5
8
P7R
JSGND4-BR
JSGND1-BR
P162JPW-OR
C165TRS-WH/RD
P162JPW-OR
C164PES-RD/WH
C163PLS-BL/WH
C161SB-WH/BK
C160JPL-WH/RD
C159STC-BL/WH
C159STC-BL/WH
P162JPW-OR
P162JPW-OR
JSGND2-BR
JSGND3-BR
GND16-BR
PLAT ROT L-GN
AUXILIARY HYD RECOVERY SIGNAL
AUX HYD PUMP
12 WAY
WHT
12
21
R
STARTER RELAY
8
21
NC
13
NO
Q
STARTER
6
P58LS RD/BK
P54ENG-BK/WH
P53LS-WH/BK
10
SERV. OR OPER. REC. 9
P22
OPER. REC. 11
ALARM+ RD/BK
ESTOP PWR-RD/BK
GND12-BR
ALARM+ RD/BK
PLAT ROT R-GN/BK
A
LSP1AO
> 5 DEG
J43
2
22
WH
BK
BR
RD
4
14
WH
BK
BR
RD
10 12
22 21
NC
14 13
WHT NO
654321
LSS2AO
RAISED OPER
J51
D82CAN+ -YL
7 11
S12SBL-BL/WH
LSS1AO
5 DEG
J50
D81CAN- -GR
3
P
LSS1RO
SEC RET OPER
J49
NORMAL SWITCH POSITION
SHOWN FOR: LSJ1EO
654321
LST1O
DRV ENABLE
J48
D81CAN- -GR
4321
S73SLD-GR/BK
87a
LST1O
DRV ENABLE
J48
J114
21
5 611 10
C64LS-OR/BK
C124SBL RD/WH
B1ENG (12 VOLT)
WH
BK
BR
RD
P21DCN-WH
18/19
CABLE
C64LS-OR/RD
C124SBL RD/WH
SJ1-WH/RD
FST1S
LOW FUEL FS
P53LS-WH/BK
4 7
C70PBR-BL/WH
C64LS-OR/BK
P23PCON-BK
S56PRV-RD
LSS2AS
RAISED
SAFETY
J47
S132LDS-BL/WH
3
TO
MICRO
TO
MICRO
OR
BL
WH
BK
BR
RD
GNDDCN-BR
1 12 2
TO
MICRO
OR
BL
WH
BK
BR
RD
C46HN-WH
8
C64LS-OR/BK
C71PBE-BL/BK
OPTIONAL RELAYS
LOCATED ON ENGINE HARNESS
LSS1RS
3' EXT
J46
S56PRV-RD
J20B
3 12 WAY 9
S12SBL-BL/WH
OPTIONAL SWING
GATE WIRING
OR
BL
WH
BK
BR
RD
GND-BR
2
P2-01 DCON ECU GND
SERV. OR
OPER. REC.
13
P7-GR/WH 12
P11
TCON MODE 14
PWR TO TCON ESTOP-BL/BK 1
PLD
OR
BL
WH
BK
BR
RD
C47OUT-WH/BK
1
OR/RD
BK/RD
OR
BL/RD
85
RED ALARM
LED
WH
BK
BR
RD
86
J20A
4 WAY
S59SBE-GR/WH
P15
ALARM GND 16
ALARM PWR 15
PCON POWER
LSP1RO
3' EXTENDED
J45
30
P21DCN-WH
U20
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
20
19
PLAT ROT R-GR/BK
PLAT ROT L-GR
18
GND16-BR
17
JIB DN-GR/BK
JIB UP-GR
GND13-BR
GND12-BR
ESTOP RET-BK
PLAT LVL DN-OR/BK
PLAT LVL UP-OR
GND6-BR
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
P20
P7R
WH
BK
BR
RD
87
GND-BR
BL/WH
BK BK
30
WH
BK
BR
RD
P52PCON-WH
WH
BK
BR
RD
C117FB-RD
85
GNDDCN-BR
TCON MODE
LSP1EO
3' FROM FULLY
EXTENDED
J44
RED
87a
C123PBD RD/BK
OUT PWR ENABLE
SJ1-WH/RD
BOOM HARN
P54ENG-BK/WH
J11 BLACK 23 PIN
P109PBTS-GR/WH
PWR TO TCON ESTOP
WH
WH/RD
WH/BK
TO FLASHING BEACON
86
LIMIT SWITCH HARN
RD
RD/WH
RD/BK
P56PRV-RD/WH
87
P21DCN-WH
P53LS-WH/BK
BK/WH
2
J12 BLACK 35 PIN
OR/BK
6 J55
PCON POWER
P6R1
P109PBTS-GR/WH
TCON
SNSR GND-BR
P11
C123PBD RD/BK
P1-23 TET ESTOP RET
P1-22 DIAG/TETHER PWR
P1-21 DIAG/TETHER GND
P1-20 TETHER FUNC ENBL
P1-19 RS232 GND
P1-18 CAN HIGH
P1-17 CAN LOW
P1-16 SPARE
P1-15 TET ESTOP PWR
P1-14 LOAD SENSR INPUT
P1-13 BOOT
BOOM HARN
18/19
CABLE
RS232 RXD
P1-12 RS232 TXD
P1-11
P1-10 CAN SHIELD
TO MICRO
SNSR GND-BR
U30
P1-09 FLASHING BEACON
P1-08 WORK LT
P_7
P1-07 P_22
P1-06
P1-05 PWR-PCON ESTOP
P1-04 OUT PWR ENBL
P1-03 HORN RELAY COIL
P7R
SNSR GND-BR
D82CAN+ -YL
D81CAN- -GR
S132LDS-BL/WH
C117FB-RD
P56PRV-RD/WH
S56PRV-RD
P23PCON-BK
C47OUT-WH/BK
J21 BLACK 23 PIN
(P15)+(ECU POWER)
WH
WH/RD
WH/BK
B
R211IGN-WH
P15
POWER FET POWER FET
A
P1-02 PCON POWER
P1-23 PWR-PCON ESTOP
P1-22
ECU POWER
BK/WH
D82CAN+ -YL
3
C46HN-WH
P1-01 PCON GND
P23PCON-BK
P1-21
P1-20
P15
OR/BK
RD
RD/WH
RD/BK
D81CAN- -GR
4
P3 - TO MICRO
POWER FET
S132LDS-BL/WH
TO WORK LIGHTS
R48LPS-RD/WH
TCON MODE
P_7
LSS2AS
RAISED
SAFETY
J47
J35-LIMIT SW HARN
P1-19
BTS650 U21
Vbb
OUT
IN
IS
P_22
LSS1RS
3' EXT
J46
J34-LIMIT SW HARN
P1-18 CAN+
P1-17 CAN-
P1-16 HRN RLY CNTRL
P1-15 OUT PWR ENBL
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07 P22
P1-06
P1-05
P1-04 P7
P1-03
P1-02 PCON PWR
P1-01 PCON GND
3
POWER FET
C46HN-WH
2
P23PCON-BK
SERVICE OR RECOVERY MODE
LSP1EO
3' FROM FULLY
EXTENDED
J44
J33-BOOM HARN
D82CAN+ -YL
D81CAN- -GR
C47OUT-WHT/BLK
C46HN-WH
P56PRV-RD/WH
S56PRV-RD
P52PCON-WH
GNDPCON-BR
P1-23 SAFE PL TILT PWR
P1-22 SAFE PL TILT GND
P1-21 PL TILT SNSR PWR
P1-20 PL TILT SNSR
P1-19 PL TILT SNSR GND
P1-18 PL LVL CYL EXT
P1-17 FOOT SW RTN
P1-16 FOOT SW PWR
P1-14 LOAD SNSR PWR
P1-15 SAFE PL TILT OUT
P1-13 LOAD SNSR SIG
P1-12 LOAD SNSR GND
P1-11 PROX KILL CMD
P1-10 PROX KILL GND
P1-09
P1-08 PROP VLV1_B
P1-07 PROP VLV1_A
P1-06 PROP VLV2_B
P1-05 PROP VLV2_A
P1-04 ON/OFF VLV3_B
P1-03 ON/OFF VLV3_A
P1-02
P1-01 VLV RTN
PIN CKT #
2
RS232_RXD
3
RS232_TXD
5
RS232_GND
J17
-
C47OUT-WH/BK
1
P52PCON-WH
GNDPCON-BR
C56PTS-RD
C23PTS-WH
P87PTS-RD
PTSRET-BR
P85PTS-GR
C84TAY-GR/BK
PLATRET-BR
S14PLU-OR
C56FTS-RD
P56FTS-RD
C88PTS-RD/BK
RD
OR
GR/YL
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
C44JD-GR/BK
C43JU-GR
C18PRR-GR/BK
C17PRL-GR
VLVRET-BRN
AXLE NOT EXT PWR
RS232 GND
CAN +
CAN -
ON CIRCUIT BOARD
DB9 CONNECTOR
1
-
J119
1
BL
P23PCON-BK
2
V
BL/BK
NO
2
BL
P56PRV-RD/WH
S56PRV-RD
1
BL/BK
S56PRV-RD
1
GNDPCON-BR
W
OFF
GROUND
2
PLAT
+
-
SWING GATE
INTERLOCK
2
2
2
GR/WH
WH
BK
BR
RD
+
POWER FET
10 DEG
SAFETY CUTOUTS
+
-
0-20DEG Y AXIS
J31 23 PIN
3
OFF
GROUND
1
PLAT
GR/WH
P52PCON-WH
4
1
SNSR GND-BR
GNDPCON-BR
1
Z
D
GR/BK
POWER FET
10 DEG -
+
C56FTS-RD
R56FTS-RD
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
AXLE NOT EXT SIG
5
3
OFF
GROUND
2
PLAT
GR
BK
RD
PLAT LEVEL DN (J81)
PLAT LEVEL UP (J80)
JIB DOWN (J79)
JIB UP (J78)
PLAT ROT CW (J76)
PLAT ROT CCW (J77)
D82CAN+ -YL
D81CAN- -GR
P1-16
P1-15
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
AXLE NOT RET RTN
DIGIN AXLE RET GND
P12
P_7R
P_6R1
DCON ECU PWR
DCON ECU GND
2
4
1
TCON
ESTOP
GR/BK
WH
BK
BR
RD
WH
BK
BR
RD
BK
RD
S56PRV(B)-RD
S56PRV-RD
V122AXO-GN/WH
S56PRV(A)-RD
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
P1-02
P1-01
LF STEER LEFT
LF STEER RIGHT
RF STEER LEFT
STEER SNSR PWR
STEER SNSR GND
RF STEER RIGHT
LR STEER LEFT
LR STEER RIGHT
BRAKE
VALVE RTN2
LR STEER SNSR
RF STEER SNSR
LR STEER SNSR
RR STEER SNSR
RR STEER LEFT
RR STEER RIGHT
AUX REVERSE
BTS621 U22
Vbb
IN1 OUT 1
IN2 OUT 2
ST
GND
Y
E
GR
21
NC
14 13
NO
TIER IV ENG OPT
GBOX HARN
3
OFF
GROUND
2
PLAT
TCON
ESTOP
18/19
CABLE
WH
BK
BR
RD
WH
BK
BR
RD
S56PRV(A)-RD
S56PRV-RD
V121AXO-GN
S56PRV(B)-RD
P2-23
P2-22
P2-21
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
P2-13
P2-12
P2-11
P2-10
P2-09
P2-08
P2-07
AUX FORWARD
OSCIL;ATE STOWED
MOTOR SPEED
LED/TOGGLE SWITCH INTERFACE PCB
4
1
SAFETY CUTOUTS
+ 80 DEG
+ 80 DEG
V122AXO-GR/WH
V121AXO-GR
WH
BK
BR
RD
S56PRV-RD
S56PRV-RD
P53LS-RD
P21DCN-WH
GND-DCN-BR
V37LFS-BL/BK
V36LFS-BL
V37RFS-BL/BK
P109ANG-GR/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
P2-06
P2-05
P2-04
VALVE RTN1
J24 20PIN
X
BL/WH
70 TO 35 DEG Y-AXIS
BK
BL
RD
BK
BL
RD
BK
BL
RD
BK
BL
RD
P2-03
P2-02
P2-01
A
B
C
J223
MOLEX
8PIN
1
LSP1RO
3' EXTENDED
J45
Y62-LF STEER LEFT (J98)
Y61-LF STEER RIGHT (J97)
Y60-RF STEER LEFT (J96)
Y59-RF STEER RIGHT (J95)
Y58-LR STEER LEFT (J94)
Y57-LR STEER RIGHT (J93)
Y56-RR STEER LEFT (J92)
Y55-RR STEER RIGHT (J91)
S14-LF STEER RIGHT
S13-RF STEER RIGHT
S12-LR STEER RIGHT
S11-RR STEER RIGHT SNSR
V29MS-RD/WH
VLVRET-BR
CAN GATEWAY
& TCON LCD
O
CAN LOW (-) P1-08 D227CAN(-) GR
CAN HIGH (+) P1-07 D228CAN(+) YL
C226TEL-BL
22
(TSx)
N
S56PRV-RD
2 1
SPARE
U
OFF
GROUND
2
PLAT
M
P1-06
FOOTSW (FS1)
#1
RUN
SERV BYPASS
2
RECOVERY
L
P1-05
Y2-BRAKE RELEASE (J106)
SERVICE
HORN (BN5)
K
REMOTE DISABLE
FOOTSWITCH STATUS
21
NC
STEER MODE
SELECT
(TS22)
J
KEY SWITCH PWR P1-04 P23PCON-BK
IGNITION STATUS P1-03 C21TEL-WH
GROUND P1-02 GND-BR
DCON PWR RD
I
SYS_POWER P1-01 B1BAT-RD
Y27-TWO SPEED MOTOR STROKE (J87)
1
120Ù
FOOTSWITCH
SPARE-WH
ON CIRCUIT BOARD
DB9 CONNECTOR
DRIVE
SPEED
(TS5)
STR MODE R-OR/BK
RD
WH/BK
1
ENGINE
SPEED
(TS4)
STR MODE L-OR
2
WH
B
DRV SPEED-RD/WH
2
DCON GND BK
A
B
19
1
P7R
BK
A
20
1
WH
AXLE
EXT/RET
(TS23)
GND2-BR
2
GR
18
2
YL
CAN LOW
NOT USED
P53LS-WH/BK
1
CAN HIGH
ENG SPEED-BK/RD
Genie Z-80 (from S/N Z8015-5654) ES0508L
P21DCN-WH
1
YL
GR
17
P21DCN-WH
J17-DRIVE CHASSIS HARN
B
SPARE-WH
P53LS-WH/BK
J18-DRIVE CHASSIS HARN
A
B
STR MODE R-OR/BK
S56PRV-RD
GNDDCN-BR
A
DRIVE
ENABLE
(TS15)
AXLE EXT-GR/WH
S56PRV-RD
GNDDCN-BR
J16-DRIVE CHASSIS HARN
15
D81CAN- -GR
P6
16
D82CAN+ -YL
P6
NOT USED
J23 10PIN
NOT USED
SLIP RING
D82CAN+ -YL
D81CAN- -GR
13
NO
AXLE RET-GR
14
6
13
LSJ1EO
PLATFORM LEVEL
CYL FULLY EXT SWITCH
(STOWED POS)
P7R
14
AXLE LS
OSCILLATE
LIMIT SWITCH
(STOWED POS)
NORMAL SWITCH POSITION
SHOWN FOR: LSA1OS
LSA2OS
PROX KILL
SWING GATE
14 13
NO
P7R
STR MODE L-OR
AXLE RS
OSCILLATE
LIMIT SWITCH
(STOWED POS)
LSA2OS
2
ENGINE
START
(TS2)
DRV SPEED-RD/WH
LSA1OS
21
NC
22
11
NO
J84
74HC08
12
P22
AXLE EXT-GR/WH
NO
22
2 74HC08
ENG SPEED-BK/RD
NO
OVERLOAD
LIMIT SW
LS18A
LS18
(SHOWN IN
OVERLOADED
CONDITION)
PLATFORM
TILT SENSOR
ASSEMBLY
1
9
B C
21
4 3 21
10
NC
14 13
22
21
1. PLAT SNSR GND
2. TILT SNSR SIG OUT
3. TILT SNSR PWR
4. TILT SW GND
5. PWR TO TILT SW
6. OUTPUT FROM TILT SW
1
GND1-BR
A
NC
14 13
PCON MANIFOLD
8
B C
22 21
J22 WHITE 23 PIN
NOT USED
A
22 21
NC
14 13
OVERLOAD
LIMIT SW
LS18A
LS18
PIN CKT #
2
RS232_RXD
3
RS232_TXD
5
RS232_GND
AXLE RET-GR
B C
4321
LSP1 PROX
PROXIMITY
KILL SWITCH
OPTIONAL
5
6
A
J110
4 3 21
4
7
B C
J109
WH
DRV ENBL-BL/WH
A
J108
J105
1
3
ECU
5
43 2 1
J82
2 1
2
1
ENG START-BK
P7
SLP_MODE
START ASST-BK/WH
4
START
ASSIST
(TS6)
DRV ENBL-BL/WH
Electrical Schematic
3
J104
1
5
AUXILIARY
PUMP
(TS1)
ENG START-BK
(from S/N Z8015-5654)
4
6
H
-
Genie Z-80
AUX PUMP-RD
P6
GENERATOR
ON/OFF
(TS17)
GEN ON/OFF-GR/WH
10
DRIVE CHASSIS
HARNESS
1
13
J107
DRIVE CHASSIS
HARNESS
DRIVE & STEERING
JOYSTICK (JC3)
2
11
J32 23 PIN
SEC BOOM UP/DWN
JOYSTICK (JC5)
HORN RET-GR
7
G
-
2
HORN PWR-RD
12
DEUTZ TD2011L04i ENGINE SHOWN
PCON
E-STOP (P2)
PRI BOOM EXT/RET
JOYSTICK (JC2)
START ASST-BK/WH
ES0508 Rev L
JIB
BOOM UP/DWN &
TURNTABLE ROTATE
JOYSTICK (JC1)
AUX PUMP-RD
9
DCON EN7
PLATFORM PLATFORM
ROTATE
LEVEL
F
+
PCON
ALARM
E
GEN ON/OFF-GR/WH
4
D
HORN RTN-GR
3
C
HORN PWR-RD
8
B
+
A
Y
Z
LOCKOUT VALVE #1 SIG
PRI BOOM LENGTH 100' STATUS
TCON MEMBRANE PANEL
PRI BOOM DOWN STATUS
AUXILIARY HYD RECOVERY SIGNAL
PWR TO TCON ESTOP
P_22
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
TO MICRO
P_30
P_22R
TO
MICRO
((~SM)+(AH))(OE)
(OE)
4
6
4
~SLP MODE (~SM)
(~SM)+(AH)
5
5 AUX HYD (AH)
74HC08
2
3
FUNC ENABLE (FE)
1
74HC08
TCON MODE(TM)
P7R
P_7
P10
TO
MICRO
P6R1
P9A
TO
TO
MICRO MICRO
Part No. 1268556
Ser vic e and R epair M anual
September 2016